PRIYADARSHINI COLLEGE OF ENGINEERING, NAGPUR

DEPARTMENT OF MECHANICAL ENGINEERING

SHIFT II

A PRESENTATION
ON
“DESIGN AND DEVELOPMENT OF 2WHEEL DRIVE FORKLIFT FOR WARE
HOUSES”

GUIDED BY
PROF. S. V. SONTAKKE
NAME OF THE PROJECTEES

1. Pranit Vairagade
2. Pratik Makode
3. Akhilesh Dabli
4. Aditya Dhage
5. Atharva Kathwate
6. Arpit Kathwate
 INTRODUCTION

• In India Factories, industries and storage go-downs need forklifts and cranes for storage and moving
large goods.
• Also there are a number of goods weighing around 25 – 30 kg that are comparatively lighter but
cannot be moved around easily by human labor.
• In India, human efforts are used to lift light weights such as cement-bags, iron-rods, etc, in this
labor feels tiredness and affect production.
• Also, in some warehouses and factories four wheel forklift is used for lifting weights which uses to
much space and difficult to handle in small spaces.
• So, To fill this need we here propose a 2 wheel drive forklift to lift and transport such medium
weight goods across factories & industrial warehouses.
• The 2 wheel drive is a fast, efficient and low power consumption vehicle that does not require
much space to move around
 LITERATURE REVIEW
Sandip Patil, Ayubkhan Pathan, Manohar Chavan, Sajid Shikalgar Prof. B. Nangare Patil, Design and Development
of Human Powered Forklift, Imperial Journal of Interdisciplinary Research (IJIR) Issue-10, Year 2017, Vol-3, ISSN:
2454-1362,pp.(293-295) In this new era Small scale industries are going toward high quality of product with
minimum cost also they are trying to reduce the material handling cost to increase the overall profit. So for effective
material handling Human powered forklift would be the excellent option to reduce energy consumption and a lot .It
has enormous advantages over others. The present In-plant goods carrier system is used for the industrial
applications which can be moved from one place to other and hence the work such as carrying goods or any other
is done within the time schedule and the particular cycle time for that operation is saved , the handling, fixing and
the other time wasted in carrying goods can be better utilized to carry out the production. They conclude that, this
project will helpful for small scale industrialists as it is easy to operate with less cost and indirectly it will save the
labor cost. savings resulting from the use of this machine will make it pay for itself with in short period of time & it
can be a great companion in any field dealing with rusted and unused metals
.
Ugale Sachin, Salvi Tushar, Lanjekar Sachin, Kshirsagar Prashant, Design, Development and Modeling of Forklift
International Journal of Engineering Research & Technology (IJERT) Issue 4, Vol. 3,April – 2014 ISSN: 2278-
0181,pp.(1234-1238). They describe the development of robotic forklift intended to operate alongside human
personnel, handling palletized materials within existing, busy, semi-structured outdoor storage facilities. The main
objective of this project is to fabricate a Mechanical forklift for material handling in industries. In this paper a
robotic vehicle is fabricated which runs to carry material from one place to another by using Radio Frequency
Technology. Nowadays in industries, forklift used with hydraulic system. To use forklift, it requires one spot guide to
guide a forklift driver because of less visibility. This paper discusses how to integrate Radio frequency identification
(RFID) technology into a forklift truck to make it wireless to increase visibility and human safety.
M. Seelinger and J. D. Yoder, “Automatic visual guidance of a forklift engaging a pallet,” Robotics and
Autonomous Systems, vol. 54, no.12, pp. 1026–1038, December 2006. From the reference of the actual forklift
named Landoll we had scaled the actual dimensions to prototype model. The mechanical structure of this
prototype model is constructed with metal plates, this structure looks like a rectangular frame& the vertical
moving mechanism that contains metal forks is assembled over the structure at front side. Since it operates
through a remote, it doesn’t contain any steering mechanism. The remote technology transfers the data by RFID.
All four motors are driven through a single, H‟ bridge DC motor drive package. All the four wheels are directly
coupled to the motor shafts independently. The DC Motors are having reduction mechanism, there by speed is
reduced and torque is increased.

Vol. 3 Issue 4, April – 2014 International Journal of Engineering Research & Technology (IJERT) Vol ISSN: 2278-
0181 in their publication they describe the development of robotic forklift intended to operate alongside
human personnel, handling pallet i materials within existing, busy, semi-structured outdoor storage facilities. The
main objective of this project is to fabricate a Mechanical forklift for material handling in industries. In this paper
a robotic vehicle is fabricated which runs to carry material f rom one place to another by using Radio Frequency
Technology. Nowadays in industries, forklift used with hydraulic system. House forklift, it requires one spot guide
to guide a forklift driver because of less visibility. This paper discusses how to integrate Radio frequency
identification (RFID) technology into a forklift truck to make it wireless to increase visibility and human safety.
 
 Exixting Machine

According to market lift machine, basically the lift machines nowadays are
provided using wire rope system and other complex hydraulic system. What our
task is to develop lift machines that not use hydraulic system as hydraulic system
is more costlier and needs high maintenance.
Also the existing model lacks in ergonomics as shown in figure as the
operator have to walk with the forklift to carry the loads, what we have done in
our project is the operator can operate the forklift along with load by standing on
the supporting frame.
 FORMULATION OF WORK
SYSTEM DESIGN OR LIFT MECHANISM
The system design comprises of development of the mechanism so that the given
concept can perform the desired operation. The system design also determines
the system components and their shape and overall dimensions , the parts are as
shown in part list above.

SELECTION OF MOTOR DRIVE

Following specification motor drive is selected to lift the load through lead screw.
Motor is an 12 volt DC motor , with following specification:
Voltage : 12 Volt DC
Power = 2309 watt
Speed = 150 rpm
Mounting : Foot mounted
DC Geared Motor, 12V, 150 RPM, Torque up to 1.5 Kg-cm
This DC Motor with Metal Gear Head is generally used in various robotics
applications , It has following electrical and mechanical specifications
SELECTION OF LEAD SCREW
Lead screw are also known as power screw is a mechanical device meant for converting
rotary motion into linear motion and translation motion for transmitting power. We
selected power screw having a single start, square threads screw with no collar friction

SELECTION OF BEARING
In selection of ball bearing the main governing factor is the system design of the drive
ie; the size of the ball bearing is of major importance ; hence we shall first select an
appropriate ball bearing first select an appropriate ball bearing first taking into
consideration convenience of mounting the planetary pins and then we shall check for
the actual life of ball bearing .

6 POWER SUPPLY
For supplying continuous power to the forklift battery is an essential part of the system.
It is use for smooth & efficient operation of unit.
SPECIFICATION OF BATTERY USED IN THE FORK LIFT
Max output voltage:- 12V
Max output current :- 2Am
Type of current :- D.C.
Charging rate :- 2.5v @2Ah.
 COMPONENTS USED
1- LIFTTING TROLLEY :
This trolley is made by the M.S. Material for loading and unloading and for lifting and
transporting the material from one place to the another place in the industry .

2-BATTERY: DRY NIKEL CADMIUM CELL

These cells consist of NIKEL and CADMIUM. It is dry and is very small in size as
compared to other batteries.

SPECIFICATION OF BATTERY
Max output voltage:- 12V
Max output current :- 8Am
Type of current :- D.C.
Charging rate :- 2.5v
3)D.C.MOTOR
DC Geared Motor, 12V, 150 RPM, Torque up to 1.5 Kg-cm
• This DC Motor with Metal Gear Head is generally used in various robotics applications ,
It has following electrical and mechanical specifications.
Specifications:
Motor type : DC with gear box.
Shaft type : circular 8mm diameter with internal hole for coupling.
Maximum torque : 1.5kg-cm at 12v = 0.187N-m
RPM : 150rpm at 12 V
Weight : 130gms
Max load current : 330Ma at 12v
4)DP/DT SWITCH :
In electrical engineering, a switch is an electrical component that can break
an electrical circuit, interrupting the current or diverting it from one
conductor to another

5) LIFTTING TROLLEY :
This trolley is made by the M.S. Material for loading and unloading and for
lifting and transporting the material from one place to the another place in the
industry.
6) Threaded Bar :
A threaded rod, also known as a stud, is a relatively long rod that is threaded on
both ends; the thread may extend along the complete length of the rod. It is
used as a linkage in a machine, to translate turning motion into linear motion.
Because of the large area of sliding contact between their male and female
members, screw threads have larger frictional energy losses compared to
other linkages.

7 GUIDE BAR: This is supporting bar help for sliding the hole mechanism from top
to bottom and vice versa. It is bright bar.
BEARING :
BALL BEARINGS :A ball bearing is a type of rolling-element bearing that uses balls to
maintain the separation between the bearing races. The purpose of a ball bearing is to
reduce rotational friction and support radial and axial loads.
MODEL DIAGRAM
 DESIGN METGODOLOGY

Design Of Input Shaft

DESIGNATION ULTIMATE TENSILE YEILD STRENGTH

STRENGTH N/mm2

N/mm2

EN 24 900 700

fs max = 0.18 fut

 
= 0.18 x 900 fs max = 162 N/mm2
OR
fs max = 0.3 fyt
 
=0.3 x 700 fs max =210 N/mm2

 
 fs act = 3.66 N/mm2 As fs act < fs all
 I/P shaft is safe under torsional load.
 2 DESIGN OF SLIDE SCREW
Power screw is mechanical device meant for converting rotary motion into
translation motion and for transmitting power. Design a lead screw having a single
start, square threads screw with no collar friction.
Initially assuming dimensions of screw , which we shall check under the given system of
forces.
Selecting material combination for screw and nut
Material Combination Coefficient of friction(starting) Coefficient of
friction(running)

Soft steel-Bronze 0.10 0.08

Basic dimensions for square threads (Ref:Pg. No. 5.69,PSG-Design Data)

Nominal Major Major Minor Pitch Area of

Dia Dia(bolt) Dia(nut) dia Core(mm2)

16 16 16.5 10 3 78.5

In lead screw for single start for 1 revolution

Lead distance(L) =pitch × No. of start
L=3×1
 
L=3mm This is the distance traveled per revolution
DESIGN OF BEARING
In selection of ball bearing the main governing factor is the system design of the drive ie;
the size of the ball bearing is of major importance ; hence we shall first select an
appropriate ball bearing first select an appropriate ball bearing first taking into
consideration convenience of mounting the planetary pins and then we shall check for
the actual life of ball bearing

BALL BEARING SELECTION.

ISI NO Brg Basic d D1 D D2 B Basic capacity

Design No
(SKF)

              C kgf Co Kgf
25A C02 6005 25 28 47 44 14 7800 5200

P = X Fr + Yfa.  
Considering 4000 working hours
  3
L = 60 n L h = 4.8  4.8 = C
m/rev 750
 C = 1265.2 N
AS; required dynamic of bearing is less than the rated dynamic capacity of bearing ;
 Bearing is safe.
 RESULT AND WORKING

When firstly we put the load which is transport to the another place on the loading and
unloading tray. After that we press the DP/DT switch the D.C. Motor start to rotate by
which the power is transfer to the wheel and start to rotate and start the vehicle move in
forward direction. Again to lift the load up to the desired height we press the DP/DT
switch the another D.C. motor start to rotate which is connected to the lead screw and
loading tray start to move from bottom to top and opposite to if we press the DP/DT
switch the motor rotate in reverse direction and loading tray move to downward direction
In this way our project is work and lift the load at minimum human effort . This project is
work safely .

RESULT- Following table shows time taken to load various loads from extreme bottom
position.
LOAD TIME TAKEN TO LIFT LOAD

0 60 Seconds

5 71.4 Seconds
10 81.6 Seconds
20 92.4 Seconds
 WORKING VIDEO OF OUR FORKLIFT

VID-20190327-WA0009.mp4 VID-20190327-WA0010.mp4
WORK PLAN SCHEDULE:

Project Literature Synopsis Workshop Design Final

discussion & review submission visit Fabricati submission
information -on &
collection Testing

Oct

Nov

Dec

Jan

Feb

March
 ADVANTAGES

•Easily transportable &movable

•Used for industrial goods purpose.

•To make warehouse internal transport easy.

•It is stable and safe under different working condition.

•To lift the material very smoothly without any impact force

Or man power.

•To reduce the cost of production.

 REFERENCES

1. Production Technology-HMT Handbook

2. Production literature- Carborundum universal Ltd
3. Machine design -R.S.Khurmi
4. Machine design - V.B.Bhandari
5. International Research Journal of Engineering and Technology (IRJET)(( e-ISSN:
23955566)(p-ISSN: 2395-0072)).
6. Masztelarz M (2010) Methods Conference Proceedings, KIBR, Poznan,
Poland29.11.2010 p 13 1–142 IS BN: 978- 83-61287-45-2
7. IJSTE - International Journal of Science Technology & Engineering | Volume 2 |
Issu 4 | October 2015
8. Vol. 3 Issue 4, April – 2014 International Journal of Engineering Research &
Technology (IJERT) VolISSN: 2278-0181.
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