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INBUILT HYDRAULIC JACK IN AUTOMOBILES
CHAPTER-1
INTRODUCTION
An inbuilt hydraulic jack is a mechanical lifting device used to lift heavy loads. An
inbuilt hydraulic jack system can be easily operated by buttons provided on the dash board of
the vehicle.An inbuilt hydraulic jack system is attached to automobile vehicle on front and
rear part of the chassis. An automobile hydraulic jack system can be easily attached to all
currently manufacture automobile chassis and frames.
The system operates from a compressed fluid reservoir tank that has connections for
the front and rear car jack outlets. Additional outlets can be added to the compressed fluid
reservoir tank for connecting a hydraulic lug wrench and another for a tire inflating hose.
Whenever the tyre failure is occurred in the vehicle then to lifting the vehicle from
ground surface is the very difficult thing for human being. And also huge human effort
required and more time taking process. Though, this inbuilt hydraulic jack system helps to lift
the vehicle from the ground level.This system will be very useful for all the persons who are
unaware regarding conventional mechanical jack or those who find it extremely difficult to
operate the jack manually in any breakdown condition.
The motive behind using this system instead of a conventional mechanical system is
the more power produced by the system and simple in design as compared to a conventional
design. As the hydraulic oil is incompressible so the lifting capacity is more in comparison
with the pneumatic system which operates on air which is compressible.
Dept.of Automobile Engineering,AAECT,Thodupuzha Page: 1

CHAPTER-2
LITERATURE REVIEW
A jack is a mechanical device used as a lifting device to lift heavy loads. Jacks
employ a screw thread or hydraulic cylinder to apply very high liner forces. A mechanical
jack is a device which lifts heavy equipment. The most common form is a car jack, floor
jack or garage jack which lifts vehicles so that maintenance can be performed .More powerful
jacks use hydraulic power to provide more lift over greater distances. Mechanical jacks are
usually rated for a maximum lifting capacity (for example, 1.5 tons or 3tons).
A screw jack is a portable device consisting of a screw mechanism used to raise or

lower the load. The principle on which the screw jack works is similar to that of an
inclined plane. There are mainly two types of jacks-hydraulic and mechanical. A hydraulic
jack consists of a cylinder and piston mechanism . The movement of the piston rod is used
to raise or lower the load. Mechanical jacks can be either hand operated or power driven.
Jacks are used frequently in raising cars so that a tire can be changed. A screw
jack is commonly used with cars but is also used in many other ways, including industrial
machinery and even airplanes. They can be short, tall, fat, or thin depending on the amount
of pressure they will be under and the space that they need to fit into.
The jack is made out of various types of metal, but the screw itself is generally
made out of lead. While screw jacks are designed purposely for raising and lowering loads,
they are not ideal for side loads, although some can withstand side loads depending on the
diameter and size of the lifting screw. Shock loads should also be avoided or minimized .
Some screw jacks are built with anti-backlash . The anti-backlash device moderates the
axial backlash in the lifting screw and nut assembly to a regulated minimum.
A large amount of heat is generated in the screw jack and long lifts can cause
serious overheating. To retain the efficiency of the screw jack , it must be used under
ambient temperatures , otherwise lubricants must be applied. There are oil lubricants
intended to enhance the equipment 's capabilities . A part from proper maintenance, to
optimize the capability and usefulness of a screw jack it is imperative to employ it according
to its design and manufacturer's instruction . Ensure that you follow the speed, load capacity,
temperature recommendation and other relevant factors for application .

2.1 The Screw Jack
The screw has a thread designed to withstand an enormous amount of pressure. This
is due to the fact that it is generally holding up heavy objects for an extended amount of
time. Once up, they normally self-lock so that they won't fall if the operator lets go, and
they hold up well to the wear of repeated use. If they are made with a ball nut, they
will last longer because there is less friction created with this type of jack. However, they
will not self-lock. This can be dangerous and handled carefully.
2.1.1 Operation
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. This turns the screw
inside the jack and makes it go up. The screw lifts the small metal cylinder and platform
that are above it. As the jack goes up, whatever is placed above it will raise as well, once
the jack makes contact. 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. An automatic screw jack has gears
inside the jack that are connected to the screw. Theses gears are connected by other gears
and bars that are turned by a power source to raise and lower the jack.
Although a jack is a simple and widely used device, the use of any lifting device is
subject to certain hazards . In screw-jack applications, the hazards are dropping, tipping or
slipping of machines or their parts during the operation. These hazards may result in
serious accidents.
The main reasons of such accidents are as follows:
(i) The load is improperly secured on the jack.
(ii) The screw-jack is over loaded.
(iii) The centre of gravity of the load is off centre with respect to the axis of the jack.
(iv) The screw-jack is not placed on hard and level surface.
(v) The screw-jack is used for a purpose, for which it is not designed.
Proper size, strength and stability are the essential requirements for the design of
the screw- jack from safety considerations.A mechanical jack is a device which lifts heavy

equipment. The most common form is a car jack, floor jack or garage jack which lifts
vehicles so that maintenance can be performed . Car jacks usually use mechanical
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. Mechanical jacks are
usually rated for maximum lifting capacity.
2.2 Scissor Jacks
Scissors jacks are also mechanical and have been in use at least since the 1930s. A
scissor jack is a device constructed with a cross-hatch mechanism, much like a scissor, to
lift up a vehicle for repair or storage. It typically works in just a vertical manner. The jack
opens and folds closed, applying pressure to the bottom supports along the crossed pattern
to move the lift. When closed, they have a diamond shape. Scissor jacks are simple
mechanisms used to drive large loads short distances. The power screw design of a
common scissor jack reduces the amount of force required by the user to drive the
mechanism . Most scissor jacks are similar in design, consisting of four main members
driven by a power screw.
Figure 2.1: SCISSOR JACK
A scissor jack is operated simply by turning a small crank that is inserted into one
end of the scissor jack. This crank is usually "Z" shaped. The end fits into a ring hole
mounted on the end of the screw, which is the object of force on the scissor jack. When
this crank is turned, the screw turns, and this raises the jack. The screw acts like a gear
mechanism. It has teeth (the screw thread), which tum and move the two arms, producing
work. Just by turning this screw thread, the scissor jack can lift a vehicle that is several
thousand pounds.

2.2.1 Construction
A scissor jack has four main pieces of metal and two base ends. The four metal
pieces are all connected at the comers with a bolt that allows the comers to swivel. A
screw thread runs across this assembly and through the comers. As the screw thread is
turned, the jack arms travel across it and collapse or come together, forming a straight
line when closed. Then, moving back the other way, they raise and come together. When
opened, the four metal arms contract together , coming together at the middle, raising the
jack. When closed, the arms spread back apart and the jack closes or flattens out again.
2.2.2 Design and Lift
A scissor jack uses a simple theory of gears to get its power. As the screw section is
turned, two ends of the jack move closer together. Because the gears of the screw are
pushing up the arms, the amount of force being applied is multiplied. It takes a very small
amount of force to turn the crank handle, yet that action causes the brace arms to slide
across and together. As this happens the arms extend upward .
The car's gravitational weight is not enough to prevent the jack from opening or to
stop the screw from turning, since it is not applying force directly to it. If you were to put
pressure directly on the crank, or lean your weight against the crank, the person would not
be able to turn it, even though your weight is a small percentage of the cars.
Bottle screws may operate by either
(i) Rotating the screw when the nut is fixed; or
(ii) Rotating the nut and preventing rotation of the screw.
2.3 Hydraulic Jack
Hydraulic jacks are typically used for shop work, rather than as an emergency
jack to be carried with the vehicle. Use of jacks not designed for a specific vehicle
requires more than the usual care in selecting ground conditions, the jacking point on the
vehicle, and to ensure stability when the jack is extended. Hydraulic jacks are often used to
lift elevators in low and medium rise buildings.

A hydraulic jack uses a fluid, which is incompressible , that is forced into a

cylinder by a pump plunger. Oil is used since it is self-lubricating and stable. When the
plunger pulls back, it draws oil out of the reservoir through a suction check valve into the
pump chamber.
When the plunger moves forward, it pushes the oil through a 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 into the cylinder. At this point the suction ball within the chamber is
forced shut and oil pressure builds in the cylinder.
2.3.1 Parts of Hydraulic Jack
Every hydraulic jack has six main components:
1.A Reservoir to hold hydraulic fluid.
2.A Pump that draws fluid from the reservoir on it's up, suction or intake stroke then creates
pressure on it's down/power stroke pushing the fluid through a delivery pipe.
3.Check Valve which after allowing fluid to pass from the reservoir to the pump now
'checks' off the return port to the reservoir and directs the pressurized fluid to the cylinders.
4.Main Cylinder where the hydraulic fluid fills up and jack works.
5.Ram Piston is forced out or upwards as the main cylinder fills with pressurized fluid.
6.The Release Valve: After the jack has done its job and it is time to release the pressure
allowing the ram piston to return back into the main cylinder is opened and the fluid is
ported back into the reservoir so the jacking cycle can be repeated.
2.3.2 Types of Hydraulic Jacks
According to the situation and position required for lifting system two types of
hydraulic jacks are used for lifting automobile.

2.3.2.1 Air Hydraulic Jack
Basically jack climb up on the jack rod (part of the lifting trestle) with the desired
pressure, to lift up the load. Its action is same as a monkey that climbs a trunk tree; i.e., first
it holds up on the trunk with its legs and lunges upward, then it holds on the trunk with its
hand and lifts its leg up. At any time, either its hands or legs have a grip on trunk, which
prevents it from falling down.
In the same manner, air hydraulic jack, air hydraulic bottle jack and jack is provided
with two pairs of jaws, a lower pair of jaws and an upper pair of jaws for an excellent
grip. During lifting, both the pairs "locked". In this position the jack can only move
upwards. At this time of lifting, the lower pair of jaws grips the trisle rod while the jack
lifts up.After completing the full stroke, the upper pair of jaws grips the trestle rod, however,
the base of the jack moves upward. During the process of lowering, any one of the pairs
is always locked.
Figure 2.2: AIR HYDRAULIC JACK
Lightweight and build for heavy-duty use. The quick-lift mechanism allows a
substantially shortened ram lifting time without load. Flow control valve prevents sudden
falls of the ram. Featured a specially processed air pump for low noise. The built-in safety
valve prevent use prevent use beyond rated capacity or lifting limit.

2.3.2.2 Bottle Jack
In a bottle jack the piston is vertical and directly supports a bearing pad that
contacts the object being lifted. With a single action piston the lift is somewhat less than
twice the collapsed height of the jack, making it suitable only for vehicles with a
relatively high clearance. For lifting structures such as houses the hydraulic interconnection
of multiple vertical jacks through valves enables the even distribution of forces while
enabling close control of the lift.
Figure 2.3: BOTTLE JACK
2.3.2.3 Floor Jack
In a floor jack a horizontal piston pushes on the short end of a bell crank, with the
long arm providing the vertical motion to a lifting pad, kept horizontal with a horizontal
linkage. Floor jacks usually include castors and wheels, allowing compensation for the
arc taken by the lifting pad. This mechanism provides a low profile when collapsed, for
easy maneuvering underneath the vehicle, while allowing considerable extension .
Figure 2.4:FLOOR JACK

2.3.2.4 Strand Jack
A strand jack (also known as strand jack) is a jack used to lift very heavy (e.g.
thousands tons or more with multiple jacks) loads for construction and engineering
purposes. Strand jacks were invented in Europe in the 1970s in the development of post
tensioning systems and are now used all over the world to erect bridges, offshore structures,
refineries, power stations, major buildings and other structures where the use of
conventional cranes is either impractical or too expensive.
A strand jack is a hollow hydraulic cylinder with a set of steel cables (strands)
passing through the open centre, each one passing through two clamps - one mounted to
either end of the cylinder.
The jack operates in the manner of a caterpillar's walk: climbing (or descending)
along the strands by releasing the clamp at one end, expanding the cylinder, clamping there,
releasing the trailing end, contracting, and clamping the trailing end before starting over
again. The real significance of this device lies in the facility for precision control.
The expansion and contraction can be done at any speed, and paused at any location.
Although a jack may lift only 1700 tons or so, there exist computer control systems that
can operate 120 jacks simultaneously, offering fingertip feel movement control over
extremely massive objects.
Figure 2.5: STRAND JACK

2.3.2.5 Pneumatic Jack
A pneumatic jack is a hydraulic jack that is actuated by compressed air - for

example, air from a compressor instead of human work. This eliminates the need for the
user to actuate the hydraulic mechanism , saving effort and potentially increasing speed.
Sometimes, such jacks are also able to be operated by the normal hydraulic actuation
method, thereby retaining functionality , even if a source of compressed air is not available.
Figure 2.6: PNEUMATIC JACK

CHAPTER-3
NEED FOR NEW DEVELOPMENT
Our survey in the regard in several automobile garages, revealed the facts that
mostly some difficult methods were adopted in lifting the vehicles for reconditioning. Now
the project has mainly concentrated on this difficulty, and hence a suitable device has been
designed, such that the vehicle can be lifted from the floor land without application of any
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 the essential tools on automobile
garages . The hydraulic jack has been developed to cater to the needs of small and medium
automobile garages, which are normally man powered with minimum skilled labor. In
most of the garages the vehicles are lifted by using hydraulic jack. This needs high man
power and skilled labour.
In order to avoid all such disadvantages, the hydraulic 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 labour can use it with ease. The D.C
motor is coupled with the Hydraulic jack by gear arrangement. The screw jack shafts
rotation depends upon the rotation of D.C motor. This is a simple type of automation
project. 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.
Degrees of automations are two types:
(i) Full automation.
(ii ) Semi automation.
In semi automation a combination of manual effort and mechanical power

1s required whereas in full automation human participation is very negligible .

3.1 Need for Automation
Automation can be achieved through computers, hydraulics, pneumatics , robotics,

etc. Automation plays an important role in mass production.
For mass production of the product, the machining operations decide the
sequence of machining. The machines designed for producing a particular product are
called transfer machines. The components must be moved automatically from the bins to
various machines sequentially and the final component can be placed separately for
packaging . Materials can also be repeatedly transferred from the moving conveyors to
the work place and vice versa. Nowadays , almost all the manufacturing processes are
being atomized in order to deliver the products at a faster rate.
The manufacturing operation is being atomized for the following reasons:
 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.

CHAPTER-4
PROPOSED METHODOLOGY
4.1 Limitations of Floor Jack
(i) Current floor jacks - Manually mounted on the vehicle frame, and necessitate
an external hydraulic pump or pneumatic system.
(ii) Permanently attached to the vehicle body - External and exposed to damage,
they can't be conveniently operated.
4.2 Problem to be So l ve d
Make the hydraulic jack convenient and efficient to use from within the automobile.
4.3 Solution to be Investigated
Inventing an automatic built-in hydraulic jack to utilize automotive power steering

fluid, and testing the effects of hydraulic pressure on effectiveness of the invention.
4.4 Objectives
Provide a safe and simple automatic hydraulic jacking system without manual effort.
Provide an alternative jacking system that can operate without external sources of
actuation, such as extra hydraulic pumps , reservoirs, or pneumatic systems. This invention
instead utilizes the vehicle power steering system which is already in place.
Provide a novel jacking system that can be operated from within the vehicle by
means of a dashboard control panel.
Provide a novel hydraulic jacking system that is directly and permanently

incorporated into the vehicle frame in such a way as to prevent the additional risk of damage
or weathering.

CHAPTER-5
INNOVATION IDEAS ON
“INBUILT HYDRAULIC JACK IN AUTOMOBILES”
An automatic built-in hydraulic jack system that utilizes the power steering
system of the vehicle to operate a set of jacks directly incorporated into indentations in the
vehicle frame.
When not in use, each jack will be fully retracted into the vehicle frame. Each jack
consists of a main jack cylinder, a slid able piston, and a jack stand and jack seal.
A pair of hydraulic lines runs from each jack to an automotive hydraulic control
valve body, which consists of a set of solenoid valves that regulate fluid flow from the
power steering pump and fluid reservoir to either the power steering rack and pinion
during normal vehicle usage or to each individual jack when the jacking system is engaged .
The jacking system can be controlled by means of a dashboard control panel

consisting of a set of switches regulating each solenoid valve within the control valve body.
5.1 Parts of Automatic Hydraulic Jacking System
5.1.1 Hydraulic fluid reservoir tank
It would be the tank for storing the hydraulic fluid and Sending it to the required
hydraulic jack for lifting the vehicle through respective hose pipes.
Figure 5.1: RESERVOIR TANK

5.1.2 Hydraulic jacks
Hydraulic jacks for lifting the vehicles, there will be two numbers of hydraulic
jacks that would be installed in the vehicle on the chassis i.e., one on the right side
and one on the left side of vehicle.
Figure 5.2: HYDRAULIC JACK
5.1.3 Hydraulic pump
Hydrostatic pumps are positive displacement pumps while hydrodynamic

pumps can be fixed displacement pumps, in which the displacement (flow through the
pump per rotation of the pump) cannot be adjusted, or variable, which have a more
complicated construction that allows the displacement to be adjusted. It will pump the
hydraulic fluid into hose pipes to the respective hydraulic jacks.
Figure 5.3: HYDRAULIC PUMP

5.1.4 Control unit
Control unit controls the direction and flow of fluid in the system. It is the
major part of the system, the control unit reliefs the excess pressure and stops the
stock of the oil filled the cylinder to return back. Control unit provides manual and
automatic control on the press and flow of fluid in the system, whether it is from
pump to cylinder or cylinder to tank. It will be the controlling unit which would
decide that in which hose line the hydraulic fluid will flow to respective hydraulic jack.
Figure 5.4: CONTROL VALVE
5.1.5 12 Volt DC battery
12 Volt DC battery will give supply to the whole hydraulic jacking system.
Figure 5.4:12 VOLT DC BATTERY
5.1.6 Hose pipes
These will be the pipe lines will help the fluid to travel from reservoir tank to
pump and pump to hydraulic jacks.
Figure 5.5: HOSE PIPE

CHAPTER-6
PROPOSED DESIGN FOR THE CONCEPT
Figure 6.1: SCHEMATIC DIAGRAM OF PROPOSED DESIGN
1. DC battery 12 Volt
2. DC Motor
3. Hydraulic pump
4. Hydraulic Fluid Reservoir
5. Control Unit
6. Hydraulic Jack
6.1. Left Front Hydraulic Jack
6.2. Right Front Hydraulic Jack
6.3. Left Rear Hydraulic Jack
6.4. Right Rear Hydraulic Jack
7. Pipes

6.1 Schematic diagram of control unit
Figure 6.2: SCHEMATIC DIAGRAM OF CONTROL UNIT
6.2 Design Process -Lowered and Retracted Hydraulic Jack
6.2.1 Lowering of hydraulic jack
Figure 6.3: LOWERED JACK
6.2.2 Retracting of hydraulic jack
Figure 6.4: RETRACT JACK

6.3 Advantages of New Design Concept
1. Man Power is will be minimized.
2. Lifting of vehicle is an easy task.
3. Tires can be easily replaced in case of tyre deflation.
4. Repairing and maintenance work is easy.
5. Less maintenance is required for the system.
6. Heat energy dissipated by the system is very less.
7. No manual work will be required for positioning and lifting of jack.
8. When not in use jacks will be retracted back in the chassis.

CHAPTER-7
METHOD USED FOR PROPESED DESIGN
Hydraulics is the science of transmitting force or motion through the medium of a

confined liquid. In a hydraulic device, power is transmitted by pushing on a confined
liquid. The transfer of energy takes place because a quantity of liquid is subject to
pressure . To operate liquid-powered systems, the operator should have knowledge of the
basic nature of liquids. Hydraulic jacks work on the basis of Pascal's Principle, named for
Blaise Pascal, who lived in the seventeenth century.
Basically, the principle states that the pressure in a closed container is the same at
all points. Pressure is described mathematically by a Force divided by Area. Therefore if
you have two cylinders connected together, small one and a large one, and apply a small
Force to the small cylinder, this would result in a given pressure. By Pascal 's Principle, this
pressure would be the same in the larger cylinder, but since the larger cylinder has more
area, the force emitted by the second cylinder would be greater. This is represented by
rearranging the pressure formula P= F/ A to F = PA.
Figure 7.1: PASCAL’S PRINCIPLE
The pressure stayed the same in the second cylinder, but Area was increased,
resulting in a larger Force. The greater the differences in the areas of the cylinders, the

greater the potential force output of the big cylinder. A hydraulic jack is simply two
cylinders connected.
An enclosed fluid under pressure exerts that pressure throughout its volume and
against any surface containing it. That's called 'Pascal's Principle', and allows a hydraulic
lift to generate large amounts of force from the application of a small force.
For lifting cars in car service station hydraulic jacks are used. High pressure liquid is
filled in the jack cylinder by hydraulic pump, due to the pressure the piston moves up. To
lower the piston valve is provided by which the liquid returns to the hydraulic tank.
Hydraulic Jacks are portable devices used for raising heavy objects by means of force
applied with a lever or screw. The hydraulic jacks are compact and lightweight units that are
used for lifting capacities.
They offer easy operation and are fast acting components. The hydraulic jacks
come with inbuilt release pedal for rapid lowering and lugs that make it easy to mount. The
heavy duty chassis prevents the jack from twisting or bending and foot pump provides
fast lift to the load. It also has a safety overload valve that prevents overloading beyond
rated capacity.
Unlike the traditional screw type jack which has to be turned with a long handle,
the hydraulic jack uses oil pressure to displace (lift) the vehicle by mere moving a lever
or handle up and down. This is very easy to operate and with this even a child can operate
and lift a vehicle using the hydraulic jack.
7.1 Hydraulic Systems
A hydraulic system contains and confines a liquid in such a way that it uses the
laws governing liquids to transmit power and do work and. components of a hydraulic
system that store and condition the fluid. The oil reservoir (sump or tank) usually serves as
a storehouse and a fluid conditioner. Filters strainers and magnetic plugs condition the fluid
by removing harmful impurities that could clog passages and damage parts.
Heat exchanges or coolers often are used to keep the oil temperature within safe
limits and prevent deterioration of the oil. Accumulators, though technically sources of
stored energy, act as fluid storehouses.

If we consider a hydraulic system which is used in earth moving equipment like

hydraulic excavators use one and only one power, i.e. hydraulic power. The excavators
control such as bucket lifting arm swiveling, boom swiveling and extension all this actions
are controlled by hydraulic circuits. To know more about the hydraulic system we will
see it with closer view. First comes an oil tank or reservoir in which hydraulic oil is
stored. The oil passes through various pipelines and after doing useful work in an actuator
the oil returns back to the oil tank. Then filter that filter soil before going to next element,
i.e. pump.
Hydraulic pump which creates the flow of oil under pressure through entire hydraulic
system. Hence assist transfer of power from which we get useful work. The valves which
are fluid control element are of different types, direction control valves, flow control valves,
pressure relief valves. These valves drive the flow of oil in the system. In actuators
(linear) the pressurized oil acts. The oil gives or transmits its power to actuators to carry
out work. The pipeline which is the functional connection for oil flow in the hydraulic
system.
Now applying the system to lift the car from one side so that wheel will be resting
on the three points, one is the piston rod of the hydraulic actuator and the two tires. The
position of each element of hydraulic system is to be arranged in a proper manner so that
it should not cause a drastic change in the four wheeler, which is now made by the car
manufacturer.
Figure 7.2: HYDRAULIC SYSTEM

The position of the hydraulic actuator is fixed. The cylinder will be permanently
mounted on the chassis centrally between two wheels on either side of the car. The oil tank
or reservoir, motor and pump could be arranged away from the cylinder as fluid is used for
the transfer of the power and motion.
7.1.1 Working
The actual working of hydraulic system that lifts the car takes place by single
press of the button provided on dashboard. When the switch is turned on the motor starts
running which is powered by a battery already available in the car. This motor facilitates
the flow of oil which is pressurized by the pump provided. This pressurized oil id then
directed to the control unit which in tum directs the flow. Distribution of the pressurized oil
is controlled by a switch on the dashboard . As the oil proceeds into the hydraulic cylinder,
it exerts a certain amount of pressure on the plunger or the ram inside the cylinder. This
exerted pressure of the oil is converted into a linear force which in tum causes the plunger
in the cylinder to move out of the cylinder. Thus ultimately the exerted pressure of the oil
is converted into linear motion of the plunger. As the plunger downwards out of the
cylinder linearly, after a definite travel of the plunger in the downward direction and once it
touches the ground it starts lifting the car.
Once the car is lifted to a desired height the tires can be changed. It is the
specialty of a simple hydraulic jack that it possesses a self-locking system i.e. once the
car is lifted to a certain height and even if the power to the jack is cut off the jack can still
hold the entire part of car that is lifted by it. And thus, the driver can easily change the tire.
Once the tire is changed, now the concern is to release the pressure in the jack which
is in the form of pressurized oil. Thus a relief valve is provided on the jack for this purpose.
But since it is impossible to actuate this valve manually when this jack is installed on the
chassis, this valve is then provided on the dashboard of the car in form of a switch which
controls the relief valve provided on the control unit of the system. Once the relief valve is
opened the oil in the cylinder which has lost its pressure energy, starts returning to the
control unit. Once the oil starts returning the control unit then sends the accumulated oil
back to the oil sump. And in this way the entire system efficiently works.

7.2 Construction of Components
A hydraulic actuator receives pressure energy and converts it to mechanical force

and motion. An actuator can be linear or rotary. A linear actuator gives force and motion
outputs in a straight line. It is more commonly called a cylinder but is also referred to as
a ram, reciprocating motor, or linear motor. A rotary actuator produces torque and rotating
motion. It is more commonly called a hydraulic motor or motor.
Cylinders are linear actuators which convert fluid power into mechanical power.
They are also known as jacks or rams. Hydraulic cylinders are used at high pressures and
produce large forces and precise movement. For this reason they are constructed of strong
materials such as steel and designed to withstand large forces.
7.2.1 Construction and working of cylinder
The cylinders fabricated for the jack have a sleeve in which the piston
reciprocates while operation . The cylinder material is cast iron and welded with an iron
base plate. The plate is gas welded below the hollow cast iron cylinder. There is an
opening for oil in the base of cylinder.
A cast iron head cover is designed for covering the cylinder from upper end. The
piston have an oil rubber ring to seal the fluid in cylinder while operation. The piston rod is
fitted with the piston and screw not on other end. The head cover is locked with the help
of circlip lock. A hole is made in the head cover to release air from the upper hollow
portion of cylinder while reciprocating motion.
When fluid pushed by the pump into the cylinder from the inlet opening given below,
it pushes the piston up in the cylinder and thus linear motion is obtained by displacement
of piston in the cylinder.
Figure 7.3: HYDRAULIC CYLINDER

7.2.1.1 Cylinder specification
Cylinder internal diameter : 65mm
Stroke : l60mm
Volume of cylinder : 332.6lml
Base plate diameter : 135mm
Piston length : 25mm
7.3 Hydraulic Pump
Hydraulic pumps convert mechanical energy from a prime mover (engine or

electric motor) into hydraulic energy. The pressure energy is used then to operate an
actuator. Pumps push on a hydraulic fluid and create flow. A rotary vane pump is used in
the jack to create the pressure difference in fluid medium . Hydraulic pumps are used in
hydraulic drive systems and can be hydrostatic or hydrodynamic. Hydrostatic pumps are
positive displacement pumps while hydrodynamic pumps can be fixed displacement pumps,
in which the displacement (flow through the pump per rotation of the pump) cannot be
adjusted, or variable displacement pumps, which have a more complicated construction that
allows the displacement to be adjusted.
7.3.1Types of h y d r a u l i c p u m p
7.3.1.1Variable delivery vane pump
The principles are the same but adjusting items can change the eccentricity of the
ring relative to the rotor. This enables the quantity of oil being pumped to be set to a
required value. The pump can be designed so that as the pressure increases beyond a set
limit, it forces the ring to a concentric position and reduces the flow to zero thus
protecting the pump. Pumps with variable delivery such as the eccentric ring vane pump,
may be designed to reduce their flow as the pressure rise.The symbol indicates that the outlet
pressure acts on the eccentric ring and pushes it against an opposing spring so that as the
pressure rises the ring gradually becomes concentric and the flow is reduced . In many
systems we do not want the flow to decrease with pressure until a dangerous pressure is

reached. In this case a simple pilot operated valve is used which opens at a preset pressure
and allows the ring to be centralized.
Figure 7.4: VARIABLE DELIVERY VANE
7.3.1.2 Radial piston pump
There are many designs for radial piston pumps. The design shown below has
three pistons arranged around an eccentric cam. The cam is part of the main shaft and
when it rotates the pistons are made to reciprocate inside cylinders which lay on a
radial line. When the piston moves inwards the space in the cylinder fills with oil
through the suction valve and the suction port. When the piston moves outward, the oil
is trapped inside and forced out to the pressure port.
Figure 7.5: RADIAL PISTON PUMP
7.3.1.3 Gear pump

These are very common and have only two moving parts. The input shaft
carries the driving gear that turns the idler gear. Oil from the suction port is carried
around in the space between the gears and at the pressure port the gears mesh and
form a barrier so the oil is forced out.

Figure 7.6: GEAR PUMP
7.3.1.4 Rotary vane pump
A rotary vane pump is a positive-displacement pump that consists of vanes

mounted to a rotor that rotates inside of a cavity. In some cases these vanes can be
variable length and/or tensioned to maintain contact with the walls as the pump rotates.
In a vane-type pump, a slotted rotor splined to a drive shaft rotates between

closely fitted side plates that are inside of an elliptical- or circular-shaped ring. Polished,
inlet as the space between vanes increases.
The oil is squeezed out at the outlet as the pumping chamber's size decreases.
Hardened vanes slide in and out of the rotor slots and follow the ring contour by
centrifugal force. Pumping chambers are formed between succeeding vanes, carrying oil
from the inlet to the outlet. A partial vacuum is created at the because the normal wear
points in a vane pump are the vane tips and a ring's surface, the vanes and ring are
specially hardened and ground. A vane pump is the only design that has automatic wear
compensation built in. As wear occurs, the vanes simply slide farther out of the rotor
slots and continue to follow a ring's contour. Thus efficiency remains high throughout the
life of the pump.
Figure 7.7: ROTORY VANE PUMP WORKING

7.3.1.5 Pump specification
Type : Rotory vane pump
Number Of blades : 10
Body Material : Aluminium
Maximum Pressure : 35 bar at 1600 rpm
7.4 Control Unit
Control unit controls the direction of flow and pressure of the fluid in the system.
It is a major part of the system, the control unit reliefs the excess pressure and stops the
stock of oil filled the cylinder to return back. Control unit provides manual and automatic
control on the pressure and flow of oil in the system. Whether it is from pump to
cylinder or cylinder to tank.
7.4.1 Construction and working of control unit
The control unit for the jack is fabricated on an aluminum block. Relief valve,
release valve and delivery valves are fitted in the control unit. Connections are made
with the help of steels pipes, robber hose and banjo bolts. When high pressure fluid
enters the control emit it passes through the delivery valve which acts as a one way valve
allows oil to flow from pump to cylinder and restrict the opposite flow of oil from
cylinder to pump .
There is a relief valve fitted between the main gallery and flow gallery the
excess pressure during the operation is drained in the reservoir by the relief valve.
There is a return valve fitted between the delivery and flow lines. This return valve
is manually operated valve used to drain the stock of the cylinder.For making the design
work we use the direction control valves. In this case we use 5/2 way direction valves.
A valve is a device that regulates the flow of fluid (gases, liquids, fluidized solids, or
slurries) by opening and closing or partially obstructing passage ways.
Directional control valves are one of the most fundamental parts in hydraulic
machinery as well and pneumatic machinery. They allow fluid flow into different paths
from one or more sources. They usually consist of a spool inside a cylinder which is

mechanically or electrically controlled. The movement of the spool restricts or permits the
flow, thus it controls the fluid flow.
The spool consists of lands and grooves. The lands block oil flow through the
valve body. The grooves allow oil or gas to flow around the spool and through the valve
body. There are two fundamental positions of directional control valve namely normal
position where valve returns on removal of actuating force and other is working position
which is position of a valve when actuating force is applied. There is another class of
valves with 3 or more position that can be spring centered with 2 working position and
abnormal position.
They are widely used in the hydraulics industry. These valves make use of
electromechanical solenoids for sliding of the spool. Because simple application of electrical
power provides control, these valves are used extensively. However, electrical solenoids
cannot generate large forces unless supplied with large amounts of electrical power. Heat
generation poses a threat to extended use of these valves when energized over time.
Many have a limited duty cycle. This makes their direct acting use commonly limited to
low actuating forces.
Often a low power solenoid valve is used to operate a small hydraulic valve
(called the pilot) that starts a flow of fluid that drives a larger hydraulic valve that requires
more force.
A bi-stable pneumatic valve is typically a pilot valve that is a 3 ported 2 position

demented valve. The valve retains its position during loss of power, hence the bi-stable
name.
Bi-stability can be accomplished with a mechanical detent and 2 opposing solenoids

or a "magna-latch" magnetic latch with a polarity sensitive coil. Positive opens and negative
closes or vice -versa. The coil is held in position magnetically when actuated.
7.4.1.1 5-port 2 way directional valves
A 5/2 way directional valve from the name itself has 5 ports equally spaced and 2
flow positions. It can be used to isolate and simultaneously bypass a passage way for the
fluid which for example should retract or extend a double acting cylinder.There are varieties
of ways to have this valve actuated. A solenoid valve is commonly used, a lever can be

manually twist or pinch to actuate the valve, an internal or external hydraulic or

pneumatic pilot to move the shaft inside, sometimes with a spring return on the other end
so it will go back to its original position when pressure is gone, or a combination of any
of the mention above.
Figure 7.8: SYMBOL OF CONTROL VALVE
Figure 7.9: 5-PORT 2 WAY DIRECTIONAL VALVE
A single solenoid is used and a spring return is installed in the other end. The
inlet pressure is connected to (1). (2) could possibly be connected to one end of the
double acting cylinder where the piston will retract while (4) is connected to the other end
that will make the piston extend. The normal position when the solenoid is de-energized is
that the piston rod is blocking (4) and pressure coming from (1) passes through (2) that will
make the cylinder normally retracted. When the solenoid is energized, the rod blocks (2) and
pressure from (1) passes through (4) and will extend the cylinder and when the solenoid is
de-energized, the rod bounces back to its original position because of the spring return.(3)
and (5) is condemned or used as exhaust.
Figure7.10: 5 PORT/2 POSITION

 1 : In l e t ( M a i n A i r S u p p l y ) .
 2 & 4 : Working/Outlet port.
 3 & 5 : Exhaust from outlet ports.
 12 : F l o w pa t h t h r o u g h t h e v a l v e fr o m po r t 1 t o 2 .
 14 : F l o w pa t h t h r o u g h t h e v a l v e fr o m po r t 1 t o 4 .
7. 5 Oil Reservoir
There is a plastic tank fitted in the jack of 700mL volume. The total oil required
in the jack is 500mL. There are two openings in the tank one is connected to the inlet of
the pump and another is connected to the return flow from the control unit.The
connections are made with the help of rubber and steel pipes .
There is a cap on the top of the tank for refilling it. Tank is mounted with the
help of thin metal sheet in the jack. Hydraulic oil of 46 grade is used in the jack. As
the pump used is vane pump so the oil of low viscosity as grade 46 is used .
Table 7.1: ISO OIL GRADE
7.6 Dc Motor
Motor is a device which converts electrical energy into mechanical energy. A DC

Motor is used in the jack to rotate the pump. DC motor is used became the current
available at vehicle battery is DC current. Motor have to terminals positive and negative.
Negative terminal of the motor is itself the body of motor.

7.6.1 Motor specification
Type : Permanent Magnet DC motor
Power input : 12 Volt DC
Power Output : 0.4KW = 0.5 HP
Rotation : Clockwise
7.7 Installations
7.7.1 Frame and base plate
All the components are mounted with the help of bolts on the iron frame and
plate and this plate is the base plate. The frame is made up of iron square bars.
Frame-1220mm x 762mrn x 250mrn (L x B x T)
Base Plate- 610mm x 762mm x lOmm (Lx B x T)
Wheel- 12 inch plastic (number of 4)
7.7.2 Connection pipes
Steel pipes of 8 mm diameter are used for connection between pump and
control unit. Return and inlet pipes are rubber pipes . The cylinder and the control unit is
connected with a flexible hydraulic hose pipe. These hose pipe have maximum working
pressure capacity of 40 Mpa.
7.7.3 Pump and motor mounting
Pump and motor are mounted on the base plate with the help of three vertical
mounting plates. These mounting plates are aluminum plates. Pump and motor are
mounted such that in order to provide the proper mating of gears used to transmit the
power. A small tolerance is provided between the gears in order to avoid the interference
of teeth and noise.

7.7.4 Control u nit mounting
Control unit is mounted in the base plate at the delivery side of the pump with
the help of a bolt. The control unit is connected with the tank as return flow with the
help of rubber pipe and also connected with the outlet of the pump with the help of steel
pipe.
7.7.5 Hydraulic f ittings and connection
Components of a hydraulic system [sources (pumps), controls(valves) and actuators

(cylinders)] need connections that will contain and direct the hydraulic fluid without
leaking or losing the pressure that makes them work. In some cases, the components can
be made to bolt together with fluid paths built-in. In more cases, though, rigid tubing or
flexible hoses are used to direct the flow from one component to the next. Each component
has entry and exit points for the fluid involved (called ports) sized according to how
much fluid are expected to pass through it.
There are a number of standardized methods in use to attach the hose or tube to
the component. Some are intended for ease of use and service, others are better for higher
system pressures or control of leakage. The most common method, in general, is to
provide in each component a female-threaded port, on each hose or tube a female-
threaded captive nut, and use a separate adapter fitting with matching male threads to
connect the two. This is functional, economical to manufacture, and easy to service.
7.7.6 Electrical c onnection
Electric connections are made with two terminal wires as positive and negative
terminals. Positive terminal wire is an insulated copper wire of thickness 5 mm and 15
feet length. This wire has a battery clip on one end which is to be connected at the
positive terminal of the battery of the vehicle. A starter switch is fitted for on off
operation of the jack. Negative terminal wire is also a copper wire of thickness 5mm and
length 3 feet. This wire is small in length and also has a clip on one end. This negative
terminal wire is connected with jack body as earth and while operation it is connected to
the vehicle body acting as a negative terminal.

7.7.7 Hydraulic oil
Power Steering Fluid is hydraulic fluid that is used for hydraulic jack system.
It flows through the hoses and power steering pump. The purpose of this fluid is to
provide power for the system, and to be a sealant and lubricant. Some are made of
water; however, most contains mineral oil. Others are made of canola, rapeseed, and
silicone oils. ISO Grade 46 oil is used and 600ml of oil is kept in the reservoir.
7.8 Working of Hydraulic Jack System
The cylinder of the jack is placed according to the lifting position of the vehicle.
After that terminal wires are connected according to polarity, positive terminal wire is
connected to the positive terminal of the battery with the help of battery clip, while
negative terminal is connected to the vehicle body at any point near to the jack. Now
after connections jack is ready to lift the load or vehicle. The actual working of
hydraulic system that lifts the car takes place by single press of the button provided on
dashboard . When the switch is turned on the motor starts running which is powered by a
battery already available in the car.
This motor facilitates the flow of oil which is pressurized by the pump provided.
This pressurized oil did then directed to the control unit which in tum directs the flow.
Distribution of the pressurized oil is controlled by a switch on the dashboard . As the oil
proceeds into the hydraulic cylinder, it exerts a certain amount of pressure on the plunger
or the ram inside the cylinder. This exerted pressure of the oil is converted into a linear
force which in turn cause the plunger in the cylinder to move out of the cylinder.
Figure 7.11: SCHEMATC DIAGRAM OF HYDRAULIC JACK SYSTEM WORKING

Thus ultimately the exerted pressure of the oil is converted into linear motion of the
plunger. As the plunger downwards out of the cylinder linearly, after a definite travel of
the plunger in the downward direction and once it touches the ground it starts lifting the
car. Once the car is lifted to a desired height the tires can be changed. Once the tire is
changed, now the concern is to release the pressure in the jack which is in the form of
pressurized oil. Thus a relief valve is provided on the jack for this purpose .
7.9 Maintenance
When the jack is not in use, keep the cylinder piston fully retracted. Store the jack
on its base and in a well-protected area where it will not be exposed to corrosive vapors,
abrasive dust, or any other harmful elements.
Visually inspect the jack before each use. Take corrective action if any of the
following problems are found:
 Cracked or damaged housing.
 Excessive wear, bending, or other damage.
 Leaking hydraulic fluid.
 Scored or damaged piston rod.
7.10 Safety Precautions
 Inspect the jack before each use; do not use the jack if it is damaged, altered, or in
poor condition.
 To prevent tipping, set up the jack on a hard, level surface.
 The load must not exceed the rated lifting capacity of the jack. Lift only dead weight.
 Center the load on the jack saddle, because off-center loads can damage the seals
and cause hydraulic failure.
 Use the jack for lifting purposes only. This jack is designed to lift loads, not support
loads. Immediately support a lifted load with jack stands.
 Use only approved hydraulic fluid, such as 32,46,68 Grade Hydraulic Oil or equivalent.

CHAPTER-8
CONCLUSION
This seminar as a working hydraulic jack performed well and according to the
design it is working with its full capacity of lifting 2 000 kg load. An inbuilt hydraulic jack
system can be easily attached to all currently manufacture automobile chassis and frames.
There is a front suspension hydraulic jack that is mounted centrally to the front suspension of
an automobile between its front wheels. There is also a rear suspension hydraulic jack that is
mounted centrally to the rear suspension of the automobile between its rear wheels. The
system operates on the hydraulic power. This arrangement has many advantages such as
maintenance and servicing of vehicle. With the help of this system the driving of vehicles
will be easy especially for ladies. Arrangement is also very useful for heavy loading vehicles
and a single person can go on a long drive. Whole system is operated by 12 volt DC battery;
hence jacks will also work, when vehicle will not in starting condition

REFERENCES
i. Dr. Ramachandra C G, Krishna Pavana, Shivraj Shet and Venugopal Reddy Virupaxappa B
2013, Vol. No.6, issue No. Vl, Dec issn : 2231-5152. : Design and fabrication of automotive
hydraulic jack system for vehicle.
ii. G.K. Patil Reference No. : 37s1373 : A case study on implementation of hydraulic jack to heavy
loaded vehicles.
iii. Types of Jack - http://wiki.seloc.org/a/Jack.
iv. Moline-Illinois, Hydraulic Basis, Deere and Company Service Publications , 1997.
v. Peter Verdone, The Basic Hydraulic System Theory, Peter Verdone.com, 2012.
vi. Moline-Illinois, Hydraulic Cylinder (Introduction) , Deere and Company Service

Publications, 1997 p 4.1.
vii. Moline-Illinois , Hydraulic Pump, Deere and Company Service Publications, 1997 P
3.1.
viii. Dr. R.K Bansal, Hydraulic Intensifier, Laxmi Publications , 2009 p 1044.
SAE ISO Oil Grade Table, www.engineeringtoolbox.com.
ix. Hydraulics & Pneumatics, BOOK 2, CHAPTER 8: Directional Control Valves, Sep
23, 2008.
x. Mueller Thomas L, Mueller Pamela A, US 07/419, 505, Patents/US4993688 , 10

Oct1989.
xi. Harcourt Smith Clyde, Patents/US2343937 A, May 4, 1942.
xii. Glen Moody, Anderson Jones, Samuel D Gray, Patents/US2473757 A, Feb 7, 1947.

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INBUILT HYDRAULIC JACK IN AUTOMOBILES

Dept.of Automobile Engineering,AAECT,Thodupuzha Page: 1

A screw jack is a portable device consisting of a screw mechanism used to raise or

Dept.of Automobile Engineering,AAECT,Thodupuzha Page: 2

2.1 The Screw Jack

The main reasons of such accidents are as follows:

(i) The load is improperly secured on the jack.

(ii) The screw-jack is over loaded.

(iv) The screw-jack is not placed on hard and level surface.

Dept.of Automobile Engineering,AAECT,Thodupuzha Page: 3

2.2 Scissor Jacks

Figure 2.1: SCISSOR JACK

Dept.of Automobile Engineering,AAECT,Thodupuzha Page: 4

2.2.2 Design and Lift

Bottle screws may operate by either

(i) Rotating the screw when the nut is fixed; or

(ii) Rotating the nut and preventing rotation of the screw.

2.3 Hydraulic Jack

Dept.of Automobile Engineering,AAECT,Thodupuzha Page: 5

A hydraulic jack uses a fluid, which is incompressible , that is forced into a

2.3.1 Parts of Hydraulic Jack

Every hydraulic jack has six main components:

1.A Reservoir to hold hydraulic fluid.

2.3.2 Types of Hydraulic Jacks

Dept.of Automobile Engineering,AAECT,Thodupuzha Page: 6

2.3.2.1 Air Hydraulic Jack

Figure 2.2: AIR HYDRAULIC JACK

Dept.of Automobile Engineering,AAECT,Thodupuzha Page: 7

2.3.2.2 Bottle Jack

Figure 2.3: BOTTLE JACK

2.3.2.3 Floor Jack

Figure 2.4:FLOOR JACK

Dept.of Automobile Engineering,AAECT,Thodupuzha Page: 8

2.3.2.4 Strand Jack

Figure 2.5: STRAND JACK

Dept.of Automobile Engineering,AAECT,Thodupuzha Page: 9

2.3.2.5 Pneumatic Jack

A pneumatic jack is a hydraulic jack that is actuated by compressed air - for

Figure 2.6: PNEUMATIC JACK

Dept.of Automobile Engineering,AAECT,Thodupuzha Page: 10

NEED FOR NEW DEVELOPMENT

Degrees of automations are two types:

(i) Full automation.

(ii ) Semi automation.

In semi automation a combination of manual effort and mechanical power

Dept.of Automobile Engineering,AAECT,Thodupuzha Page: 11

3.1 Need for Automation

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

The manufacturing operation is being atomized for the following reasons:

 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.

Dept.of Automobile Engineering,AAECT,Thodupuzha Page: 12

4.1 Limitations of Floor Jack

4.3 Solution to be Investigated

Inventing an automatic built-in hydraulic jack to utilize automotive power steering