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.

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. So we selected MOTORISED HYDRAULIC JACK
. The working of MOTORISED HYDRAULIC JACK is described below,
It consist of DC motor. The electric power is used to run the motor by the
help of 12 Volt DC supply . One end of jack lever is connected to Dc motor
output shaft through the crank wheel. . The power from the dc supply is given to
electric motor from the 12V DC power supply..
.
Thus, by introducing this project on market dual advantage is obtained one
is the easy operation is made and usage of manual work is avoided..

ADVANTAGES

1. Single person is enough to operate this efficiently to lift the tyre.

2. Easy and efficient handling of this unit without wastage or damage to any
other parts.
3. Increase the unit life.
4. Least maintenance of the equipment.
5. Need not require any individual work place.
6. Can be worked in the work spot.

COMPONENTS USED FOR DIGITAL HYDRAULIC JACK

S.N
O

COMPONENTS
USED

MATERIAL

SIZE

QUANTIT
Y

M.S.FABRICATED
BASE 8MM THICK
PLATE

MILD STEEL

200X200X8
MM
(WXHXD)

12VDC MOTOR WITH

BUILT IN SPEED
REDUCTION GEAR
BOX

ALUMINIUM

10KG
TORQUE

CRANK DISC

MILD STEEL

70MM DIA
X
8MM
THICK

ELECTRICAL
CONTROL
POWER SUPPLY

COPPER

3 AMPS

1
1

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.

2.Crankand connecting rod mechanism;

A crankshaft has one (or more) offset sections where a connecting rod is
attached around it. The connecting rod moves back-and-forth (or up-and-down)
ONCE for every rotation of the crankshaft. The crank will always move in a circle,
moving the connecting rod in a smooth sine wave like motion. The power can flow
in either direction.
3.Frame Stand
This base frame stand made in 25mm size x 1.8mm thick M.S.square tube
material base plate and is used to hold the entire mechanism and support the
motor also.

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 .

The vehicle tyre is moved up slowly

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.

The construction of dc motor and generator are similar. However their

external appearance may be somewhat different. A motor has a rather closed frame
because it is may be operating in dusty environment and unskilled workers may be
working in its vicinity.

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.

Because its induction and

contribution to back emf, the series field helps in reducing the fluctuations of
current drawn from mains.

POWER SUPPLY UNIT

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. A commonly used circuit for supplying large
amounts of DCpower is the bridge rectifier. A bridge rectifier of four diodes (4 x
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.

DETAILS OF
HYDRAULIC JACK;

DETAILS OF HYDRAULIC JACK;

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.

It is imperative that these must function at peak efficiency by regular

cleaning and flushing of foreign particles which enter into the hydraulic
system and may clog the delicate valves, damage the seals and affect the
functioning of other elements in the hydraulic circuit.

C. A pump by itself would be useless without a system of VALVES to govern

the flow of hydraulic oil to perform the desired function.

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
function. The movement of Ram is always in line with cylinder under
pressure.

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.

The five fundamental components already illustrated and described

combined together perform the specified job by a synchronous follow
through of their individual functions.

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.

The oil flows back into the

reservoir shown in the diagram in page 1.

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

7. Single person is enough to operate this efficiently to remove the tyre.

8. Easy and efficient handling of liner puller without wastage or damage to the
tyre and to any other parts.
9. Increase the puller life.
10.Least maintenance of the equipment.
11.Need not require any individual work place.
12.Can be worked in the work spot.
13.Suited for lifting load.

MECHANICAL SPARE
PARTS DIAGRAM

SAFTY,CARE AND
MAINTENANCE

BASIC SAFETY RULES FOR HYDRAULIC JACKS;

The nature of lifting operation should determine the choice of jacking equipmentintegral or remote control pump type jacks. Capacity and the hydraulic lifting
stroke are vital aspects to be carefully determined before selection.

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).

D. Never drop (shock) load on the hydraulic ram.

E. Never go under a load supported by hydraulic ram only.

F. Never extend the hydraulic ram by means other than the pump.

G. Never use hydraulic equipment with observed leakages.

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.

Raising the Jack

Turn the release valve in clockwise direction till tight, use end of slotted operating
handles. Start pumping with a regular handle movement. Make only few fast and
rapid download delivery strokes, Jack handle slightly downward, in case the
delivery does not close instantly. Check that the saddles rests firmly against the
Jacking point.

Lowering the Jack

Turn the release valve SLOWLY anticlockwise.

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.

Making Jack ready for use

VANJAX Hydraulic Jacks are supplied ready for use. Unlock the release valve
half a turn and operate the pump few times to flush the hydraulic unit free from
airlocking.

DOS AND DONTS

Air

Dos
venting is an

precaution

for

the

important Under

no

Donts
circumstances

the

successful equipment should be used beyond

performance of any hydraulic jack rated capacity or rated stroke. It is

or hydraulically operated device, in the interest of the user and for the
equipment or system.

protection of his costly equipment to

ensure correct selection of the
capacity and restricting the stroke

within the rated stroke length.

All couplings and other fasteners Do not forcibly hammer
should be properly tightened.

fit

accessories if falling short by a

fraction of the required length or
spread.

Use the next higher size

equipment.

Abuse of accessories

and attachments are hazardous both

for the equipment and the personnel.
At all times the entire equipments Do not expose the equipment to
should be kept free from dust areas of excessive heat or where
through regular systematic cleaning.

dirt, dust and heavily laden fumes /

smoke

are

prevalent.

If

the

equipment is used in such areas it is

absolutely essential to service it at
once.
Check oil level each time before Do not refill without a reliable
use.

strainer

Every time the hydraulic hose is Do not use brake fluid as refill.
attached to the pump and the ram
cylinder assembly unit, it should be
thoroughly flushed.

Release

valve

to

be

properly Do not hammer to open guide nuts.

tightened by turning it in clock-wise Open by guide nut spanner.

direction when applying load. For
releasing

pressure

open

release

valve gradually by turning it in anticlockwise direction.

The equipment must be centrally

loaded. The pressure screw in a
hydraulic
puller
should
be
absolutely perpendicular to the axis
of the load.
As refill we recommend IOC Code
No. Servo System 32 and 46, HPC
Hydrol 0232 or any other
equivalent.

Do not apply extra force to close the

release valve.
Normal hand
pressure is enough.

Do not use fluffy cloth or cotton

waste for cleaning cylinder ram,
valve, pump and oil tank.

ADVANTAGES

ADVANTAGES

1.Single person is enough to operate this efficiently to lift the load.

2.Easy and efficient handling of this unit without wastage or damage to the
vehicle,machine and to any other parts.
3.low maintenance cost and life of equipment also increased..
4Least maintenance of the equipment.
5.Need not require any individual work place.
6Can be worked in the work spot.

7.Suited for lifting the any light load and heavy load vehicle for removing the
tyre..

DIS ADVANTAGES

1. CARE should be taken for maintenance of batteries..

2. Leakage of oil is not repairable one .
3. The spare parts for the hydraulic jack is not available.

PAINTING AND FINISHING

FINISHING AND PAINTING

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.

FINISHING OPERATION BEFORE PAINTING

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

1. D.C. MOTOR 12 VDC

1600,00

2. hydraulic jack

1800.00

3 . M.S. Fabricaed housing unit

600.00

4. power supply 12VDC

1600.00

5. Painting cost

200.00

6. transport cost

200.0
TOTAL COST

6000.00

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.

Once again we express our sincere thanks to our staff members.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. WORKSHOP TECHNOLOGY

-HAJRA CHOWDRY

2. PRODUCTION TECHNOLOGY

-R.S. KHURMI

3. MACHINE SHOP TECHNOLOGY

-S.S.MANIAN

4. JIG AND FIXTURE DESIGN

- R.K.JAIN

PHOTO VIEW

PHOTO VIEW