PEDAL DRIVE FORKLIFT

A REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE

REQUIREMENTS FOR THE DEGREE OF
BACHELOR OF TECHNOLOGY
In
Mechanical Engineering
By
NAME REGD NO
RAJESH KUMAR GIRI 1401216072
RAJESH NAYAK 1401216073
RONAK CHOUDHURY 1401216074
SAMIR RANJAN DHAL 1401216075
SATYA NARAYANA SAHU 1401216076

Of
7th Semester
Under the Supervision of
Prof. U.C. Paltasingh
Mech. Engg. Dept.

Department of Mechanical Engineering

Padmanava College of Engineering
Rourkela - 769002 (India)
November,2017
 ACKNOWLEDGEMENT

I/We express my sincere gratitude and indebtedness to the project guide Prof. U.C.

Paltasingh (Coordinator / Supervisor), Mechanical Engineering Department for his initiative

in the field of research, for his valuable guidance, encouragement, moral support, and affection for

the successful completion of this work. His sincere sympathies and kind attitude always

encouraged me/us to carry out the present work firmly.

My/Our special thanks to Prof. S. Mohanty, H. O. D, Mechanical Engineering

Department for providing all kind of necessary facilities to carry out the project work.

NAME REGD NO

Rajesh kumar Giri 1401216072

Rajesh Nayak 1401216073

Ronak Choudhury 1401216074

Samir Ranjan Dhal 1401216075

Satya Narayan Sahu 1401216076

 PADMANAVA COLLEGE OF ENGINEERING, ROURKELA

CERTIFICATE

This is to certify that the work entitled in this report " FORKLIFT "Presented by was work

carried out by him under my supervision in partial fulfilment of the requirements for the award

of the degree of Bachelor of Technology, during the session 2017-2018 in the department of

Mechanical Engineering, Padmanava College of Engineering, Rourkela.

To the best of my knowledge, the matter embodied in the report has not been submitted

to any other University/ Institute for the award of any degree or diploma.

Prof. U.C.Paltasingh Prof. S. Mohanty

Coordinator / Supervisor H.O.D

 ABSTRACT

Many industries use forklifts for lifting heavy goods etc. These are applicable for large

scale industries and highly automated industries. Since the small scale industries

requires repeated movement of load from one station to another the use of these fork

lift will not be economical. Hence we decided to design a fork lift which helps small

scale industries in transporting the load in easy and cost efficient way. The idea was to

lift and shift the materials on shop floor where very low frequency of shifting is required

and the object being heavy enough for humans to shift the materials. Where the lifting

could be done by crank provided in a convenient approachable place near the operator.

And once the load is lifted by the fork, the vehicle could be propelled with operator

itself by his pedaling effort just like a bicycle. Brakes are also operational by hand near

the seat so that its convenient enough. The vehicle could be steered easily without any

problem in the job floor as well meant for flat floor.

 CONTENTS

Title Page. No
CERTIFICATE 1
ACKNOWLEDGEMENT 2
ABSTRACT 3

CHAPTER 1 - INTRODUCTION
1.1 History of Fork Lift

1.2 Definition

1.3 Types of Fork Lift

CHAPTER 2 - LITERATURE SURVEY

CHAPTER 3 - MATERIALS AND METHODS
3.1 DESCRIPTION OF PARTS
3.2 WORKING MECHANISM
3.3 SIDE VIEW OF PEDAL OPERATED FORK LIFT
3.4 DESIGN CALCULATIONS

CHAPTER 4 - DRAWINGS
4.1 MAIN FRAME
4.2 SLIDER FRAME

4.3 TIE ROD

4.4 STUB AXLE

4.5 STUB AXLE FRAME

CONCLUSION
FUTURE SCOPE
REFERENCE
CHAPTER I
INTRODUCTION
 INTRODUCTION

1.1 History of Fork Lift: -

A fork lift truck, also known as a forklift and other names, is a powered industrial truck.
Its main purpose is for material handling within facilities or compounds, especially the capability
to lift loads to be positioned at height as well as to lower them as needed. Fitted with specific
attachments, the fork lift truck also is used to perform other related functions such as the transfer
loads from slip sheets onto pallets, as well as to clamp them or to invert them.

Since their introduction in the early 20th Century, fork lift trucks have played a powerful
role in materials handling. This article provides an overview of lift trucks, including their
evolution, an overview of the various categories of lift trucks, and considerations for safe operation
Fork lift trucks first emerged in the late 19th Century. These were low lift trucks that raised
platforms just a few inches high. Typically, these were used for moving material within a shop,
such as work-in-progress. High lift trucks emerged in the late 1910s, and truck design
improvements continued to take root. In the 1930s, tier trucks allowed the stacking of loads,
allowing for greater storage efficiency. Growth of lift usage was slow in the 1930s, however.
During the Great Depression, labor was freely available while capital for investment was much
harder to source. Then in World War 2, the use of forklift trucks became a strategic part of the war
effort.
With manpower shortages resulting from wartime enlistment, the forklift and an operator (and
increasingly female operators as World War 2 progressed) could do the work of many men,
increasing productivity versus manual handling. After the War's conclusion, lift trucks emerged as
a mainstay of material handling equipment.

Forklifts and pallets left behind by the U.S. military in Australia became the basis for the
Commonwealth Handling Equipment Pool (CHEP), which became the worlds largest pallet
pooling company.

1.2 Definition : -

Forklifts are the material handling devices which are used to transport the load from one
station to another.
Forklifts are either powered by gasoline, propane, or electricity. Electric forklifts rely on
batteries to operate. Gasoline or propane forklifts are sometimes stronger or faster than
electric forklifts, but they are more difficult to maintain, and fuel can be costly.
Rough terrain forklifts have the highest lifting capacity of all forklifts and heavy duty tires
like those found on trucks, making it possible to drive them on uneven surfaces outdoors.
Several Types of forklifts are:

1) Pallet jack
2) Rider motorized pallet truck
3) High lift pallet trucks
4) Front rider pallet trucks
5) Automated guided vehicle

Forklifts are rated for loads at a specified maximum weight and a specified forward center of
gravity. This information is located on a nameplate provided by the manufacturer, and loads
must not exceed these specifications. In many jurisdictions it is illegal to alter or remove the
nameplate without the permission of the forklift manufacturer.
An important aspect of forklift operation is that it must have rear-wheel steering. While this
increases maneuverability in tight cornering situations, it differs from a drivers traditional
experience with other wheeled vehicles. While steering, as there is no caster action, it is
unnecessary to apply steering force to maintain a constant rate of turn.

Another critical characteristic of the forklift is its instability. The forklift and load must be
considered a unit with a continually varying center of gravity with every movement of the load.
A forklift must never negotiate a turn at speed with a raised load,
where centrifugal and gravitational forces may combine to cause a disastrous tip-over
accident. The forklift is designed with a load limit for the forks which is decreased with fork
elevation and undercutting of the load (i.e., when a load does not butt against the fork "L"). A
loading plate for loading reference is usually located on the forklift. A forklift should not be
used as a personnel lift without the fitting of specific safety equipment, such as a "cherry
picker" or "cage".

1..3 Types of forklift: -

Pallet jacks :-
Pallet jacks are the most basic form of fork lift. Pallet jacks are intended to move heavy
or light pallets for relatively short distances. These do not have powered propulsion
system but are powered by the operator pushing and pulling the track. It consists of
hydraulic lifting mechanism controlled by the operator.

Rider motorized pallet trucks: -

These are used when the transport distance is too great to make walkie practical, and are
ideal for frequent movement over extended distances. The rider truck travels at high
velocities presents an extreme hazard to the operator and any one near the lift is the major
problem.
 High lift pallet trucks :-
These are used as an alternative to forklifts, often performing same functions such as
moving loads on shelving.

Front rider pallet trucks :-

These are pallet trucks where operator stance is located between the front of the lift
where the forks are, and the rear of the lift where battery is stored. This provides some
protection to the operator. With a physical barrier in front and behind the operator, there
is less injury to the operator.

Automated guided vehicle (AGV) :-

It represents the future of materials handling technology. AGVs do not require operators but
travel along a route that is demarcated by frequency sensors, light beams or induction tape.
The removal of the operator from the fork lift saves the companys wages, and can decrease
the hazard level associated with the material handling responsibilities.

Automated guided vehicle (AGV)

 DESCRIPTION OF PARTS

1. Body or main chassis :-

The body is rectangular in section. It is made of mild steel. The front part is
called as channel where the frame travels. It is welded with stainless steel for
easy movement of the frame and to reduce friction.

2. Frame :-
It is rectangular in section. It is made of mild steel. Its dimensions are
1500x900mm. The frame reciprocates inside the channel and is welded with
the fork which carries the load.

3. Fork :-
The fork is made of mild steel and is welded to the channel .The dimensions
of the fork are 600mm. The load to be lifted is placed on the fork and the
frame along with the fork is lifted using worm gear mechanism.

4. Worm and worm wheel :-

This is used to lift the frame through chain. The material used is cast steel.
The worm is rotated by cranking the pulley.
The worm wheel is also called as worm gear. The material used is phosphor
gear bronze. The output from the gear is connected with chain and is fixed to
the frame to lift the load.

5. Hand wheel :-
The hand wheel consist of pulley and is welded to the rod. The diameter of
the pulley is 200 mm. It is made of cast iron. The rotation of the pulley in
turn rotates the worm.

6. Gear box :-
The gear box consist of two shafts and idler shaft with five gears. The
material used for the gears is EN8. The gears are covered with the plates
made of mild steel.

7. Pedal :-
The input to the shaft which enables the gear to rotate inside the gear box is
achieved through pedaling. The pedals are made of steel. It is situated such
that operator feels comfortable to operate.

8. Sprockets :-
There are two smaller diameter sprockets with diameter 65 mm which
provides input to the gear shaft and two larger diameter sprockets with
diameter 160 mm is provided at the output and is welded to the axle. The
material used for the sprockets is alloy steel.
 9. Tie rods :-
The tie rods are made of mild steel. The dimensions is 400x20mm. It is
connected to bell crank which is linked to the stub axle.

WORKING MECHANISM

The fork lift which we have designed consists of three main mechanisms:

Lifting mechanism using Worm gear

Steering mechanism
Pedaling mechanism for the movement of the vehicle

We have designed the system for 500N and it can be used in small scale industries.

Lifting mechanism: -

The load will be lifted by using worm gear assembly wire rope system. It consists of worm,
worm wheel, wire rope and a pulley for cranking. The rotation of pulley enables the worm
to rotate which in turn rotates the worm wheel. The wire rope which is fixed to the output
of gear helps in lifting the load placed in the fork of the fork lift. The below figure shows
lifting mechanism.

Fig 1 Flowchart of lifting mechanism

It consists of bell crank lever, tie rods, steering rod consisting of eccentric pivot pin.
One end of both the tie rods are connected to the pivot pin and the other end of the tie rod is
connected to the longer arm of the bell crank lever on each side. The short arm holds the front
wheels. The pivot pin is connected to the steering rod. The wheels are steered by rotating steering
wheel.

Pedal Mechanism :-
This mechanism comprises of gear box. The gear box contains two shafts (one for input and
other for output).It consist of 5 gears including an idler gear. Due to pedaling the input shaft
rotates, hence gear fixed to the shaft rotates which mates with the gear on the output shaft. An
idler gear is placed to move the vehicle in forward direction. When the lever direction is changed
the 3 gear assembly with idler gear is disengaged and the other two gears are engaged which
enables the vehicle to move in reverse direction.

Fig 2 flowchart of pedal mechanism

Side view of pedal operated fork lift.
 DESIGN CALCULATIONS

WORM GEAR :-

n1 = rpm of worm = 45 rpm

z1 = teeth of worm =1

n2 = rpm of gear = ?

z2 = teeth of gear = ?

P = power
 DRAWINGS

MAIN FRAME
SLIDER FRAME

TIE ROD
STUB AXLE STUB AXLE FRAME
SPECIFICATION
 CONCLUSION

The Pedal operated Fork lift which we have designed is limited to load capacity of
2500 N further improvements can be made in designing the chain blocks of higher
dimension to increase the lifting capacity .

Weight reduction of the structure is reduced to 30% of the whole structure.

The specialty of the existing design is that no need of providing the counter weight
for balancing since the load being lifted is transferred to the rare part of the
structure through the chain block being mounted on the ISMC which rests on the
pipe frame.

Also further improvement in the movement of the vehicle can be obtained by

replacing the chain drive with differential system.

FUTURE SCOPE

Hydraulics can be applied for lifting mechanism.

Pedaling mechanism can be replaced by using an engine.

The load capacity of the system can be increased by increasing the worm
dimensions.

Other steering mechanism such as rack and pinion etc can be introduced.
 REFERENCE

Design of machine elements by J.B.K.DAS.

Design data hand book by K.Mahadevan & K. Balaveera reddy.

Kulwiec,R.A,1985, Materials handling hand book ,wiley interscience.