HUMAN

POWERED
FORKLIFT
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 CONTENTS OF PRESENTATION
 Abstract
 Introduction
 Aim of Project
 Literature Review
 Working principal of project
 Components & Material
 Views of Project
 Estimation cost with Detail
 Outcome of the project
 Pictures while Assembling
 Advantages
 Scope for the future work
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 ABSTRACT
Forklift handle more material and transfer one place to another place. Because of
forklift it is possible that one operator is sufficient for material handling.
A mixture of material handling systems is in the use, exact from that entirely
physical to the ones that are semi-automatic but manually controlled.
Forklifts have revolutionized warehouse work. They made it possible for one
person to move thousands of pounds at once. This is the general description of a
normal forklift truck.
To enhances the technology further, this prototype module is constructed with
remote technology, there by the operator can walk along with the forklift for better
visibility & the container can be placed accurately (precision position). This
increases the safety of the operator.
Human Powered forklift consist of frame which is made of iron square bars which
are welded together to form structure. The wheels are provided for turning
purpose.

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 INTRODUCTION
A fork lift truck, also known as a forklift and other names, is a powered
industrial truck. It's 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.
In general, the forklift can be defined as a tool capable of lifting hundreds
of kilograms of weight. A forklift is a vehicle similar to a small truck that has
two metal forks on the front used to lift cargo.
The forklift operator drives the forklift forward until the forks push under
the cargo, and can then lift the cargo several feet in the air by operating the
forks.
The forks, also known as blades or tines, are usually made out of steel and
can lift up to a few tons. Forklifts are machines that use levers and/or pulleys
to lift significant weights. if not longer.

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Fig 1: Forklift

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 Types Of Forklift:-
1. Counterbalance: – Counterbalance forklifts
are the most common trucks used in virtually
all material handling capacities. Counterbalance
forklifts are straight forward appliance that features
dual forks for heavy loads and bulky items.

2. Three-Wheel Counterbalance:– These forklifts

feature three wheels as opposed to four in their
counterbalance forerunners. Three-wheel counterbalance
forklifts are ideal for narrow aisles as they have enhanced maneuverability for tight
spaces.

3. Reach Trucks – Reach trucks are known for what they are named after, their
extended lift height. Reach trucks are optimal in any warehousing situation with
high rise.
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4. Pump Trucks – Pump trucks are considered
a bit of a throwback. Pump trucks are primarily used
as a pallet jack but do not use any electric power to
lift any materials. Instead, pump trucks rely on good
old-fashioned manual labour as the operator “pumps”
the jack to lift the skids with their own force.

5. Powered Pallet Trucks – Conversely, the

powered pallet truck is a modernized innovation of
a pump truck. The powered pallet truck does all the
heavy lifting for you! Mirroring functionality of a
pump truck, powered pallet trucks are ideal for
skids and small packages that need to be stored or
transported.

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6. Side loaders – Side loaders are primed to
operate in narrow aisles as well.  Side-lines feature
forks which are mounted to the side of the truck and
are designed to pick up wide or long loads that would
cumbersome to the typical forklift. Just like many
other species of forklift, these to come in various
forms. First is the Enclosed Cab that is frequently
used outdoors and the Stand-Up which is geared to
handle indoor assignments.

7. Teletrucks – Short for telescopic hander forklift, these devices are another option for
users that are tasked with high lifting or facilitation of mezzanine storage. These devices
are often mistaken for cranes and are able to reach heights and angles that standard lift
trucks cannot.

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 AIMS OF FORKLIFT

 To help peon or any other workers to transport the good in less time, in
less effort, easily and comfortably.

 To modify and improve mechanism of forklifts.

 To make effective loading/ unloading of goods

 To make activities/ procedure environment friendly.

 To reduce cost of operation by substituting gasoline engine.

 Increase safety at workstation.

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 LITERATURE REVIEW

 This article is developed by “Yanko SLAVCHEV”, Proceedings of the

international Conference on Manufacturing System. Article presents a
research, conducted by 3-D computer models and the finite element
method (FEM), on the stressed state of fork arms of forklifts. Several
modes of attachment to the carrying plate have been taken into
consideration. Special interest has been paid to the stressed state of the
folded region and the console welds for arms attachment.

 Material Handling Equipment Selection Using Weighted Utility Additive

Theory by Prasad Karande, Shankar Chakraborty using weighted utility
additive method to solve material handling equipment solution. This
method is compare with drive by the past research with provide the its
potentiality, applicability and accuracy to solve machining problem.
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 Design development and modeling forklift by Ugale Sachin, Salvi Tushar,
Lanjekar Sachin, Kshirsagar Prashant fabricated a forklift by using ratio
frequency technology. This makes it wireless and increase visibility as well
as safety. A transmitter which are present in this forklift able to control a
forklift from 15 feet we can not use this forklift more than 15 feet distance.

 Chunshan when forklift is loading and unloading it is directly under all cargo
weight and finished the goods fork, handling , lifting. It is mainly composed
of door frame outrigger and cargo, guide wheel chain and lifting oil cylinder.

 Aashish kumar L Sharnagat1, M.S.Tufail. we developed of robotic forklift to

handle palletized material using local sensing so that it needs electricity.

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 Design and development of human powered forklift by Sandip patil,
Ayubkhan Pathan, Manohar Chavan, Sajid Shikalgar, Prof.B.Nangare Patil.
A small scale industry going towards high quality of product with minimum
cost and also minimize material handling cost . so human powered forklift
is better option.this forklift easy to operate with less cost and indirectly it
save labor cost.

 Matthew Sparkers For companies trying to be sustainable and carbon

neutral, warehousing and distribution can be difficult. It’s fine to make
green products, but it is more difficult to find a green way to get them into
store. If you are serious about reducing emission , and your product does
not weight too much, then this human powered forklift may good option.
You can move and lift pallets entirely with human power and get that gas
or diesel forklift out of your warehouse.

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 High Risk Work A Guide to forklift safety by Government of South Australia
counter balance forklift are usually supported at three points called ‘triangle
of stability’. The front left wheel the front right wheel and middle of rear axle
at the pivot pin connected to the steer axle make an imaginary triangle. This
is important because the center of gravity must remain within this triangle
of stability. If the COG fall outside the triangle the forklift will tip over.

 Design And Structure Analysis Of Mechanical Forklift Using ANSYS Software

by Prof. kshirsagar Prashant. we study the structure analysis of the forklift
using ANSYS software. Theoretical calculation is compare with ANSYS
software analysis is done to verify due to this select the forklift material as
mild steel due to high specific stiffness and strength. Lift by the fork it tried
to deform and bend in a particular direction so in order to prepare design of
forklift.

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 WORKING PRINCIPLE OF FORKLIFT
 Forklift is a small industrial vehicle, having a power operated forked
platform attached at the front that can be raised and lowered for
insertion under a cargo to lift or move it. Forklifts serve the needs of
various industries including warehouses and other large storage
facilities.

 Forklifts are powered by electric battery. Some Forklifts allow the

operators to sit while driving and operating the machine while others
require the operator to stand. It is being extensively used throughout
the industry for transporting materials and goods.

 Lifting Mechanism:
Motor and pulley are attached to the two main vertical structures called
the "masts." However, the actual forks that carry the load are attached
to the main body of the forklift .

 Controls
We used push button and 2 way switch to lift and release fork.

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 COMPONENTS & MATERIALS

1. Supporting frame
Material : M.S. plate

2. Electric motor
Material: standard
Capacity : 12 v DC , 350 RPM

3. Wheel
Material: Polyurethane
Size: 10”

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4. Battery

5. Caster

6. Nut & Bolts

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 Forks:-
Forks are the main part of forklift, which used for lift the load in the forklift. As per the ITA
(International Technology Association) standard there are mainly two types of fork joints are
in the use. We has used pin mount for our light weight.

1) Pin mounts (Low Load)

2) Hook Mounts (High Load)

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VIEWS OF HUMAN POWERED FORKLIFT
Front view Top View

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Left Hand Side View Right Hand Side View

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 ESTIMATED COST WITH DETAILS
S No. ITEMS QUANTITY COST

1. Structure 15 4000

2. Motor 1 1000

3. Wheel 4 300

4. Nut & Bolt 10 200

5. Battery 1 1000

6. Paint 1 130

7. Pulley 1 300

8. 2 way switch 1 30

9. Push Button 1 20

10. Wire 5 20

TOTAL COST :- ₹ 7000/-

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 OUTCOME OF THE PROJECT

 From the on top of knowledge it's conjointly ascertained that using

forklift, problems of workers and transporters will be solved. From the
practicality we’ve found reliable way to satisfy needs of workers. From the
on top of literature survey, it's evident that the design and model of
Human Powered forklift is a unique concept .It can Withstand Unit amount
of load without failure. Using High torque motor can increase
Effectiveness and load Capacity of Forklift. Goods from small warehouses
or college campus can be easily transported with minimum time.
 Effectiveness compared to pure human power is better. Overall It`s
reliable and Effective concept for Forklift Technology.

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 ADVANTAGES
 Suitable for indoor use.
 Longer life.
 Reduced man power.
 Eco friendly operation.
 Minimum noise level.
 Maintain better control of material management.
 Reduced product damage.
 Less working place.
 Increase productivity.

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 SCOPE FOR FUTURE WORK

 Future Possibilities……
 Robotic arms can be added to the fork to simplify work of loading and
unloading objects on the fork.
 Forklift can be converted to the complete automated machine, by which
we can control the forklift from the cabin as like AGV (Automated Guided
Vehicle).
 Loading capacity can be improved of forklift by enlarge the size of fork and
with the help of heavy torque motor.
 Hydraulic system can be attached behalf of mechanical system.
 Chain drive or gear drive system can be used at the place of Rope drive
mechanism.
 Total height of lifting can be maximized.
 Cost of Product can be reduced by Batch production.
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