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CONTROLLED
MOTORIZED
HYDRAULIC JACK
INTRODUCTION
INTRODUCTION
This is a self assessment test on the part of the students to assess his
competency in creativity.
During the course of study, the student is put on a sound theoretical
foundation of various mechanical engineering subjects and of course, to a
satisfactory extent. Opportunities are made available to him to work on different
kinds of machines, so that he is exposed to various kinds of manufacturing process.
As a students learn more and more his hold on production technology
becomes stronger. He attains a stage of perfection, when he himself is able to
design and fabricate a device.
This is the project work. That is the testimony for the strenuous training,
which the student had in the institute. This assures that he is no more a student, he
is an engineer.
This report discuses the necessity of the project and various aspects of
planning , design, selection of materials, fabrication, erection, estimation and
testing.
OBJECTIVE
Objective;
SYNOPSIS
SYNOPSIS
According to the current situation, scarcity of LABOUR , SALARY, and for
automatic operation elimination of labour work is neccessory for the future days.
In current situation , car tyre is removed for repair work a jack is must and it is
operated by manually and not so easy to handle. Thus to tackle both situation
which is mentioned above.
The working of
MOTORISED
ADVANTAGES
MATERIAL
SIZE
QUANTITY
MILD STEEL
200X200X8
MM
(WXHXD)
ALUMINIUM
10KG
TORQUE
CRANK DISC
MILD STEEL
70MM DIA
X
8MM
THICK
ELECTRICAL
CONTROL
POWER SUPPLY
COPPER
3 AMPS
USED
1
M.S.FABRICATED
BASE 8MM THICK
PLATE
1
5
HANDLE
MILD STEEL
12MM DIA
HYDRAULIC JACK
MILD STEEL
2 TON
CAPACITY
METAL PRIMER
PAINT
LITRE
CONSTRUCTION
CONSTRUCTION
The projects consists of
1. M.S . BASE FRAME
2. HYDRAULIC JACK
3. 12 VDC POWER SUPPLY
4. 12 VDC motor.
5. ELECTRIC POWER SUPPLY .
4. 12 DC Motor
This DC motor is shunt type 12 DC motor. It has high torque and low speed
capacity. The DC Motor drives transmitted to the handle of the jack.
. This motor is having built in type speed reduction gear box unit. It has high
torque and low speed capacity. The electrical supply to the motor is from 12 V DC
power supply.
WORKING PRINCIPLE
WORKING PRINCIPLE
The working principle of this MOTORISED HYDRAULIC JACK is explained in
block diagram
230 V AC
Power supply
12 VDC
12VDC MOTOR
HYDRAULIC JACK
This MOTORISED JACK has one 12 VDC motor. This DC motor drive is
transmitted to the jack unit through the CRANK mechanism .. The vehicle tyre ias
lifted up and down by pressing the switch in the panel board. The 12 V DC supply
is supplied from the 12 V DC motor.
without any sack .
PRINCIPLE OF DC
MOTOR
PRINCIPLE OF DC MOTOR
A DC motor is a dc machine working as a motor to convert dc electrical
energy into mechanical energy (dc) motor are very commonly used in cars, trucks,
aircrafts, etc. They are also used in large ratings, where wide range of speed
control is necessary.
When a conductor is carried a current and in lying in magnetic filed. Force
acting on the conductor. This is the principle of a Dc motor. The conductor is
housed in armature slots and current is applied from the dc source through brushes
and commutator. The field poles provide the magnetic field.
TYPES OF DC MOTOR
TYPES OF DC MOTOR
DC Shunt Motor:
This motor has medium starting torque, a speed regulation of 5 10 % and
excellent adaptability to adjustable speed service. It can be used for constant speed
drives like pumps, fans blowers, etc,. However for all these applications, a 3 phase
induction motor is preferable, because it ;is cheaper, more rugged and requires
lesser maintenance than dc motor. However a dc shunt motor is cheaper for low
speed drives. Moreover, whenever a wide range of speed control is required, dc
shunt motor is used. The main application of dc shunt motor is in steel and
aluminium, rolling mills and ward Leonard speed control system.
Dc Series Motor:
This motor has a very high starting torque. Moreover it speed decreases
with increase in load torque. So that its power input remains more or less constant.
It is best suited for hoist cranes and traction. Speed control is generally obtained
through armature control. They are used for battery-powered vehicles.
Compound Motor:
A differential compound is rarely used. The characteristics of a cumulative
compounds motor depend on the relative strength of series and shunt fields. It has
good starting torque and dropping speed load characteristic. They can be used
for pulsating loads needing flywheel action, viz. shears, conveyors, crushers,
hoists, plunger pumps, etc., Whenever the supply voltage is likely to vary
considerably, a compound motor is preferred.
contribution to back emf, the series field helps in reducing the fluctuations of
current drawn from mains.
IN4007) are used to achieve full wave rectification. Two diodes will conduct
during the negative cycle and the other two will conduct during the positive half
cycle, and only one diode conducts. At the same time one of the other two diodes
conducts for the negative voltage that is applied from the bottom winding due to
the forward bias for that diode. In this circuit due to positive half cycle D1 & D2
will conduct to give 0.8V pulsating DC. The DC output has a ripple frequency of
100Hz. Since each alteration produces a resulting output pulse, frequency = 2 x 50
Hz. The output obtained is not a pure DC and therefore filtration has to be done.
The DC voltage appearing across the output terminals of the bridge rectifier
will be somewhat less than 90% of the applied rms value. Normally one alteration
of the input voltage will reverse the polarities. Opposite ends of the transformer
will therefore always be 180 degree out of phase with each other. For a positive
cycle, two diodes are connected to the positive voltage at the top winding.
FILTERING CIRCUIT:
Filter circuits which is usually capacitor acting as a surge arrester always
follow the rectifier unit. This capacitor is also called as a decoupling capacitor or a
bypassing capacitor, is used not only to short the ripple with frequency of 120Hz
to ground but also to leave the frequency of the DC to appear at the output. A load
resistor R1 is connected so that a reference to the ground is maintained.
REMOTE CONTROL
DETAILS
These are no
security chips from the RF solutions range encryption ICs can be used to encode
and decode the data.
These modules will suit one to one and multi node wireless links in
applications including car and building security,
CIRCUIT DETAILS
The circuit diagram for this micro controller board is shown below,
INTRODUCTION:
All the electronic components starting from diode to Intel ICs only work
with a DC supply ranging from +5V to +12V. We are utilizing for the same, the
cheapest and commonly available energy source of 230V-50Hz and stepping
down, rectifying, filtering and regulating the voltage.
STEP DOWN TRANSFORMER:
When AC is applied to the primary winding of the power transformer, it can
either be stepped down or stepped up depending on the value of DC needed. In our
circuit the transformer of 230V/15-0-15V is used to perform the step down
operation where a 230V AC appears as 15V AC across the secondary winding.
Apart from stepping down voltages, it gives isolation between the power source
and power supply circuitries.
RECTIFIER UNIT:
In the power supply unit, rectification is normally achieved using a solid
state diode. Diode has the property that will let the electron flow easily in one
direction at proper biasing condition. As AC is applied to the diode, electrons only
flow when the anode and cathode is negative. Reversing the polarity of voltage
will not permit electron flow.
during the negative cycle and the other two will conduct during the positive half
cycle, and only one diode conducts. At the same time one of the other two diodes
conducts for the negative voltage that is applied from the bottom winding due to
the forward bias for that diode. In this circuit due to positive half cycle D1 & D2
will conduct to give 0.8V pulsating DC. The DC output has a ripple frequency of
100Hz. Since each alteration produces a resulting output pulse, frequency = 2 x 50
Hz. The output obtained is not a pure DC and therefore filtration has to be done.
The DC voltage appearing across the output terminals of the bridge rectifier
will be somewhat less than 90% of the applied rms value. Normally one alteration
of the input voltage will reverse the polarities. Opposite ends of the transformer
will therefore always be 180 degree out of phase with each other. For a positive
cycle, two diodes are connected to the positive voltage at the top winding.
FILTERING CIRCUIT:
Filter circuits which is usually capacitor acting as a surge arrester always
follow the rectifier unit. This capacitor is also called as a decoupling capacitor or a
bypassing capacitor, is used not only to short the ripple with frequency of 120Hz
to ground but also to leave the frequency of the DC to appear at the output. A load
resistor R1 is connected so that a reference to the ground is maintained. C1, R1 is
for bypassing ripples. C2, R2 is used as a low pass filter, i.e. it passes only low
frequency signals and bypasses high frequency signals. The load resistor should be
1% to 2.5% of the load.
1000f/25V : for the reduction of ripples from the pulsating
10f/25V
0.1f
TRANSFORMER
BRIDGE
POSITIVE
RECTIFIER
CHARGE
CAPACITOR
5V
REGULATOR
MOTHER
BOARD
12V
REGULATOR
DISPLAY
BOARD
RELAY
VOLTAGE REGULATOR:
The voltage regulators play an important role in any power supply unit. The
primary purpose of a regulator is to aid the rectifier and filter circuit in providing a
constant DC voltage to the device. Power supplies without regulators have an
inherent problem of changing DC voltage values due to variations in the load or
due to fluctuations in the AC linear voltage. With a regulator connected to the DC
output, the voltage can be maintained within a close tolerant region of the desired
output. IC7812 and 7912 is used in this project for providing +12V and 12V DC
supply.
5 TO 12 V DC DRIVE CARD
DETAILS OF
HYDRAULIC JACK;
A Hydraulic Jack or for that matter any device using Hydraulic Power in its
simplest possible shape consists of five fundamental components.
A. The Hydraulic Reservoir storing the Hydraulic Oil (Oil is used as the
medium to transmit force and motion-such fluids are called Hydraulic Oils)
should be thoroughly clean, whether integrally built-in or used as a separate
tank.
B. Pump, either of the integral or the remote control type, comprises of highly
precision engineered pump plunger, cylinder, suction and delivery valves,
safety valves with conical or steel balls matched with micron tolerances.
Very often O Rings and special seals are used, made from specially treated
leather or synthetic nitrile rubber or Teflon or other modern substitutes for
greater resistance to wear and sealing ower.
D. The transmission of hydraulic oil from the reservoir by the pump through the
valves to Ram & Cylinder which converts the hydraulic pressure into a
mechanical force is by means of a Hydraulic Circuit which is nothing but a
network of passages in hydraulic systems. These passages are formed with
the help of Steel Tubes, Flexible Hydraulic Hoses or through internal holes
or cavities in metal blocks. It is of the utmost importance that the circuit is
always leak proof as well as free from obstacles. Each joint or coupling
must be securely tightened or replaced forthwith. No air lock or foreign
particles should be allowed to interrupt or block the free flow of hydraulic
oil.
E. All hydraulic cylinders consists of two basic elements the outer housing is
called the Cylinder body and the inner sliding elements is called the Ram
(or piston or plunger) which actually converts the hydraulic pressure into
mechanical force and transmits to the desired point for performing the
Hydraulic Oil is pumped into the cylinder and as more and more oil is forced
into the cylinder pressure builds up and when enough oil is forced into the
cylinder the resultant pressure will cause the ram, plunger or piston to move
and consequently lift, press, push, pull or bend any object any object as the
case may be.
The Ram and Cylinder are also precision engineered and mostly fitted with
high quality seals which give it the necessary compression holding capacity
and prevent leakages.
1. The release valve is closed tightly to ensure flow of oil from the pump to the
cylinder only.
2. As soon as the pump is operated oil is sucked in from the reservoir. As the
Pump Plunger is raised up oil passes from the reservoir into the pump
cylinder with the Suction Valve opening up to allow oil from reservoir to
enter into pump cylinder.
3. When the Pump Plunger is pressed down the Delivery Valve opens up to
allow the passage of oil from the pump into the cylinder, at the same time
the suction valve automatically closes to prevent oil returning to the
reservoir.
4. By repeating the above two operations successively more and more oil is
pumped into the cylinder resulting in the generation of pressure by the action
of the load being lifted.
5. When the load is desired to be lowered the pressure within the cylinder is
released by operating the Release Valve.
6. Due to neglect or other causes pressure within the system may continue to
increase beyond the predetermined safe working limit. To prevent damage to
the system a safety relief valve is located between the cylinder and the
reservoir excessive pressure by the opening up of the safety valve and
discharge of oil into the reservoir (very often the safety overload preventive
relief valve is located in between the reservoir and the pump the pump
automatically cuts off without delivery of oil to the cylinder due to
generation of excessive pressure within the pump).
The simple diagram shown in page 1 shall help to understand the working of
the hydraulic system in a more graphic manner.
ADVANTAGES
ADVANTAGES
MECHANICAL SPARE
PARTS DIAGRAM
SAFTY,CARE AND
MAINTENANCE
Lifting any load calls for precise and safe jacking points. Jack should be centrally
loaded eccentric loading causes dangerous accidents and damages beyond repair.
The world over prudent safety minded operators observe the flowing basic safety
rules :
A. To overpower the load, whether one or a dozen cylinders are used to lift the
load, the cylinder lifting capacity should be two times the weight of the load.
This allows for a reduction in the oil pressure, prevents strain and possible
break-down of the cylinder.
B. To balance the load, for large, heavy and uneven loads, it is recommended
dividing the load evenly between a number of cylinders. These cylinders
should be placed beneath the load at points providing the best support, balance
and stability. For example, to lift a 200-tonns load, the necessary 400-tonnes
capacity could be handled by four 100-tonnes cylinders.
C. Never raise the hydraulic ram beyond the specified stroke (lift).
F. Never extend the hydraulic ram by means other than the pump.
H. Use safety lock nut type jacks for supporting load on jack for long periods.
I. Use steel plates or heavy wooden sleepers where ground surface is soft and
yielding
J. Do not disturb the factory preset internal safety valve provided for preventing
overloading.
K. Do not load more than 50% of the rated head capacity on the toe (claw) of toe
lifting jacks.
Positioning the Jack
Jack should be centrally loaded, jack base and upper jacking point must be in level.
Jack Storage
Retract ram completely, close oil filler, keep the Jack away in a safe clean place.
Caution
Do not use the Jack beyond rated capacity and lift mentioned on the name plate.
venting
precaution
is
for
Donts
an
the
important Under
no
circumstances
the
not
forcibly
hammer
fit
equipment.
Abuse of accessories
are
prevalent.
If
the
valve
to
be
pressure
open
release
The equipment must be centrally Do not apply extra force to close the
loaded. The pressure screw in a release valve.
Normal hand
hydraulic
puller
should
be pressure is enough.
absolutely perpendicular to the axis
of the load.
As refill we recommend IOC Code Do not use fluffy cloth or cotton
No. Servo System 32 and 46, HPC waste for cleaning cylinder ram,
Hydrol 0232 or any other valve, pump and oil tank.
equivalent.
ADVANTAGES
ADVANTAGES
DIS ADVANTAGES
JOB PREPARATION
Before welding, remove any bend in the L angle with the sludge hammer on
the anvil block. Then it is cut to the required length with the hacksaw blade and
fabricated to required dimensional shape with arc welding.
After welding, any slag on the welded area is removed with the chipping
hammer and cleaned with the metal wire brush. Then all the surfaces are rubbed
with the emery sheet.
Metal primer is applied on the surfaces with the brush. After drying the metal
primer, the second coating is applied with the paint.
COST ESTIMATION
COST ESTIMATION
1600,00
2. hydraulic jack
1800.00
600.00
1600.00
5. CONTROLLER CIRCUIT
3000.00
1200.00
7.Painting cost
200.00
200.0
TOTAL COST
10200.00
CONCLUSION
CONCLUSION
We make this project entirely different from other projects. Since concepts
involved in our project is entirely different that a single unit is used to various
purposes, which is not developed by any of other team members.
By doing this project we gained the knowledge of fabrication work and how
the welding is doing and material selection for particular components etc.,
It is concluded that any fabrication work can be done with the help of
welding.
We have successfully completed the project work on using welding work at
our Institute.
BIBLIOGRAPHY
BIBLIOGRAPHY
1. A course in Automobile Technology
R.S. Khurumi
2. Electrical Technology
B.L. Theraja
3. Automobile Technology
R.S. Khrumi
4.Automobile engineering
R.B. Gupta
5.Automobile Engineering
Kirpal Singh
6.Automobile Engineering
John chikkiri
1. http://researchdesignlab.com
2. The 8051 Micro controller and embedded systems
Muhammad Ali Mazidi
Janice Gillispie Mazidi
3. The 8051 Micro controller Architecture, Programming & Applications
a. Kenneth J. Ayala
4. Fundamentals of Micro processors and Micro computers
a. B. Ram
5. Micro processor Architecture, Programming & Applications
i. Ramesh S. Gaonkar
6. Electronic Components
i. D.V. Prasad
PHOTO VIEW
PHOTO VIEW