Literature Survey
Literature Survey
LITERATURE SURVEY
Screw type mechanical jacks were very common for jeeps and trucks of
World War II vintage. For example, the World War II jeeps (Willis MB and Ford
GPW) were issued the "Jack, Automobile, Screw type, Capacity 1 1/2 ton",
Ordnance part number 41-J -66. This jacks, and similar jacks for trucks, were
activated by using the lug wrench as a handle for the jack's ratchet action to of the
jack. The 41 -J-66 jack was carried in the jeep's tool compartment. Screw type
jack's continued in use for small capacity requirements due to low cost of
production raise or lower it. A control tab is marked up/down and its position
determines the direction of movement and almost no maintenance.
While he would eventually have over 50 British patents with titles ranging
from knitting machines to rifles, it was Whitworth’s work on screw cutting
machines, accurate measuring instruments and standards covering the angle and
pitch of screw threads that would most influence our industry today.
Whitworth’s tools had become internationally famous for their precision and
quality and dominated the market from the 1850s. Inspired young engineers began
to put Whitworth’s machine tools to new uses. During the early 1880s in Coati
cook, a small town near Quebec, a 24-year-old inventor named Frank Henry Sleeper
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designed a lifting jack. Like da Vinci’s jack, it was a technological innovation
because it was based on the principle of the ball bearing for supporting a load and
transferred rotary motion, through gearing and a screw, into linear motion for
moving the load. The device was efficient, reliable and easy to operate. It was used
in the construction of bridges, but mostly by the railroad industry, where it was able
to lift locomotives and railway cars.
Local Coati cook industrialist, Arthur Osmose Norton, spotted the potential
for Sleeper’s design and in 1886 hired the young man and purchased the patent. The
„Norton‟ jack was born. Over the coming years the famous „Norton‟ jacks were
manufactured at plants in Boston, Coati cook and Moline, Illinois. Meanwhile, in
Alleghany County near Pittsburgh in 1883, an enterprising Mississippi river boat
captain named Josiah Barrett had an idea for a ratchet jack that would pull barges
together to form a „tow‟. The idea was based on the familiar lever and fulcrum
principle and he needed someone to manufacture it. That person was Samuel Duff,
proprietor of a local machine shop.
Together, they created the Duff Manufacturing Company, which by 1890 had
developed new applications for the original “Barrett Jack” and extended the product
line to seven models in varying capacities.
Over the next 30 years the Duff Manufacturing Company became the largest
manufacturer of lifting jacks in the world, developing many new types of jack for
various applications including its own version of the ball bearing screw jack. It was
only natural that in 1928, The Duff Manufacturing Company Inc. merged with A.O.
Norton to create the Duff-Norton Manufacturing Company.
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Fig.1.1 Air Motor Power Jack
There was clearly potential for using this technology for other applications
and only 10 years later, in 1940, the first worm gear screw jack, that is instantly
recognizable today, was offered by Duff-Norton, for adjusting the heights of truck
loading platforms and mill tables. With the ability to be used individually or linked
mechanically and driven by either air or electric motors or even manually, the first
model had a lifting capacity of 10 tons with raises of 2 or 4.
Since then the product has evolved to push, pull, lift, lower and position loads
of anything from a few kilos to hundreds of tones. One of the biggest single screw
jacks made to date is a special Power Jacks E-Series unit that is rated for 350
tones–even in earthquake conditions for the nuclear industry.
More recent developments have concentrated on improved efficiency and
durability, resulting in changes in both lead screw and gearbox design options for
screw jacks.
3
A screw jack that has a built-in motor is now referred to as a linear actuator
but is essentially still a screw jack. Today, screw jacks can be linked mechanically
or electronically and with the advances in motion-control, loads can be positioned
to within microns. Improvements in gear technology together with the addition of
precision ball screws and roller screws mean the applications for screw jacks today
are endless and a real alternative to hydraulics in terms of duty cycles and speed at a
time when industry demands cleaner, quieter and more reliable solutions.
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CHAPTER 2
POWER SCREWS
A power screw is a mechanical device used for converting rotary motion into
linear motion and transmitting power. A power screw is also called translation
screw. It uses helical translatory motion of the screw thread in transmitting power
rather than clamping the machine components.
2.1 Applications
There are three essential parts of a power screw, viz.screw, nut and a part to
hold either the screw or the nut in its place. Depending upon the holding
arrangement, power screws operate in two different ways. In some cases, the screw
rotates in its bearing, while the nut has axial motion. The lead screw of the lathe is
an example of this category. In other applications, the nut is kept stationary and the
screw moves in axial direction. Screw-jack and machine vice are the examples of
this category.
2.2 Advantages
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(iv) The manufacturing of power screw is easy without requiring specialized
machinery. Square threads are turned on lathe. Trapezoidal threads are
manufactured on thread milling machine.
(v) Power screw provides large mechanical advantage. A load of 15 kN
can be raised by applying an effort as small as 400 N.Therefore, most of the
power screws used in various applications like screw-jacks, clamps, valves
and vices are usually manually operated.
(vi) Power screws provide precisely controlled and highly accurate linear
motion required in machine tool applications.
(vii) Power screws give smooth and noiseless service without any maintenance.
(viii) There are only a few parts in power screw. This reduces cost and increases
reliability.
(ix) Power screw can be designed with self-locking property. In screw-jack
application, self locking characteristic is required to prevent the load from
descending on its own.
2.3 Disadvantages
(i) Power screws have very poor efficiency; as low as 40%.Therefore, it is not
used in continuous power transmission in machine tools, with the exception of the
lead screw. Power screws are mainly used for intermittent motion that is
occasionally required for lifting the load or actuating the mechanism.
(ii) High friction in threads causes rapid wear of the screw or the nut. In case of
square threads, the nut is usually made of soft material and replaced when worn out.
In trapezoidal threads, a split- type of nut is used to compensate for the wear.
Therefore, wear is a serious problem in power screws.
6
2.4 Forms of Threads
There are two popular types of threads used for power screws viz.
square and I.S.O metric trapezoidal.
(i) The efficiency of square threads is more than that of trapezoidal threads.
(ii) There is no radial pressure on the nut. Since there is no side thrust, the
motion of the nut is uniform. The life of the nut is also increased.
(i) Square threads are difficult to manufacture. They are usually turned on lathe
with single-point cutting tool. Machining with single-point cutting tool is an
expensive operation compared to machining with multi-point cutting tool.
(ii) The strength of a screw depends upon the thread thickness at the core
diameter. Square threads have less thickness at core diameter than trapezoidal
threads. This reduces the load carrying capacity of the screw.
(iii) The wear of the thread surface becomes a serious problem in the
service life of the power screw. It is not possible to compensate for wear in
square threads. Therefore, when worn out, the nut or the screw requires
replacement.
2.4.3 Advantages of Trapezoidal Threads
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operation compared to machining with single point -cutting tool. Therefore,
trapezoidal threads are economical to manufacture.
(ii) Trapezoidal thread has more thickness at core diameter than that of square
thread.Therfore; a screw with trapezoidal threads is stronger than equivalent screw
with square threads. Such a screw has large load carrying capacity.
(iii) The axial wear on the surface of the trapezoidal threads can be compensated
by means of a split -type of nut. The nut is cut into two parts along the diameter. As
wear progresses, the looseness is prevented by tightening the two halves of the nut
together, the split -type nut can be used only for trapezoidal threads. It is used in
lead-screw of lathe to compensate wear at periodic intervals by tightening the two
halves.
(i) The efficiency of trapezoidal threads is less than that of square threads.
(ii) Trapezoidal threads result in side thrust or radial pressure on the nut. The
radial pressure or bursting pressure on nut affects its performance.
There is a special type of thread called acme thread. Trapezoidal and acme
threads are identical in all respects except the thread angle. In acme thread, the
thread angle is 29° instead of 30°.The relative advantages and disadvantages of
acme threads are same as those of trapezoidal threads.
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(i) It has higher efficiency compared to trapezoidal threads.
(iii) The axial wear at the thread surface can be compared by means of spit-type nut.
(iv) A screw with buttress threads is stronger than equivalent screw with either
square threads or trapezoidal threads. This is because of greater thickness at the
base of the thread.
The buttress threads have one disadvantage. It can transmit power and
motion only in one direction. On the other hand, square and trapezoidal threads can
transmit force and motion in both directions.
Square threads are used for screw-jacks, presses and clamping devices.
Trapezoidal and acme threads are used for lead -screw and other power
transmission devices in machine tools. Buttress threads are used in vices, where
force is applied only in one direction. Buttress threads are ideally suited for
connecting tubular components that must carry large forces such as connecting the
barrel to the housing in anti air-craft guns.
Sq 30 x 6
It indicates single-start square threads with 30mm nominal diameter and 6mm pitch.
9
Tr 40x7
Multiple threaded power screws are used in certain applications where higher
travelling speed is required. They are also called multiple start screws such as
double-start or triple-start screws. These screws have two or more threads cut side
by side, around the rod.
Tr 40 x 14 (P7
In above designation,
Lead=14mm pitch=7mm
Tr 40 x 14 (P7) LH
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2.6 Terminology of Power Screw
(i) Lead: The lead is defined as the distance, measured parallel to the axis of the
screw, that the nut will advance in one revolution of the screw. It is denoted
by the letter „l‟. For a single-threaded screw, the lead is same as the pitch, for
a double-threaded screw, the lead is twice that of the pitch, and so on.
(ii) Nominal diameter: It is the largest diameter of the screw. It is also called
major diameter. It is denoted by the letter„d‟.
(iii) Core diameter: It is the smallest diameter of the screw thread. It is also
called minor diameter. It is denoted by the letters „dc‟.
(iv) Helix angle: It is defined as the angle made by the helix of the thread
with a plane perpendicular to the axis of the screw. Helix angle is related to
the lead and the mean diameter of the screw. It is also called lead angle. It is
denoted by α
Imagine that one thread of the screw is unwound and developed for one
complete turn. The thread will become the hypotenuse of a right-angled triangle,
whose base is (πdm) and whose height is the lead (l ).Considering this right -angle
triangle, the relationship between helix angle, mean diameter and lead can be
expressed in the following form,
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(vi) The load W always acts in vertically downward direction. When the
load W is raised, it moves up the inclined plane. When the load W is lowered,
it moves down the inclined plane.
(vii) The load W is raised or lowered by means of an imaginary force P
acting at the mean radius of the screw. The force P multiplied by the mean
radius (dm/2) gives the torque required to raise or lower the load. Force P is
perpendicular to load W.
2.7 Torque Requirement- Lifting Load
(iii) Frictional force μN: Frictional force acts opposite to the motion. Since the load
is moving up the inclined plane, frictional force acts along the inclined plane in
downward direction.
(iv)Effort P: The effort P acts in a direction perpendicular to the load W.It may act
towards right to overcome the friction and raise the load.
When the load is being lowered, the following forces act at a point on the
inclined plane:
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(iii) Frictional force μN: Frictional force acts opposite to the motion. Since the load
is moving down the inclined plane, frictional force acts along the inclined plane in
upward direction.
(iv) Effort P: The effort P acts in a direction perpendicular to the load W.It should
act towards left to overcome the friction and lower the load.
The torque required to lower the load is negative. It indicates a condition that
no force is required to lower the load. The load itself will begin to turn the screw
and descend down, unless a restraining torque is applied. This condition is called
“overhauling” of screw.
A positive torque is required to lower the load. Under this condition, the load
will not turn the screw and will not descend on its own unless effort P is applied. In
this case, the screw is said to be „self-locking ‟. The rule for self-locking screw is
as follows:
(i) Self-locking of screw is not possible when the coefficient of friction (μ) is low.
The coefficient of friction between the surfaces of the screw and the nut is reduced
by lubrication. Excessive lubrication may cause the load to descend on its own.
(ii) Self-locking property of the screw is lost when the lead is large. The lead
increases with number of starts. For double-start thread, lead is twice of the pitch
and for triple threaded screw, three times of pitch. Therefore, single threaded is
better than multiple threaded screw from self-locking considerations.
Self-locking condition is essential in applications like screw-jack.
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2.10 Efficiency of Square Threaded Screw
Refer to the force diagram for lifting the load, illustrated in Fig. .Suppose the
load W moves from the lower end to the upper end of the inclined plane. The output
consists of raising the load.
(i) The efficiency of square threaded screw increase rapidly up to helix angle of
20°.
(ii) The efficiency is maximum when the helix angle between 40 to 45°.
(iii) The efficiency decreases after the maximum value is reached.
(iv) The efficiency decreases rapidly when the helix angle exceeds 60°
(v) The efficiency decreases as the coefficient of friction increases.
There are two ways to increase the efficiency of square threaded screws. They
are as follows:
(i) Reduce the coefficient of friction between the screw and the nut by proper
lubrication, and
(ii) Increase the helix angle up to 40 to 45° by using multiple start threads.
However, a screw with such helix angle has other disadvantages like loss of self-
locking property.
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2θ = 29°
There is a basic difference between the force acting on the thread of square
and trapezoidal threads. In case of square threads, W is the axial load raised by the
screw. It is also the normal force acting on the thread surface. In case of trapezoidal
or acme threads, these two forces are different. The axial force on the screw is W,
while the normal force on the thread surface is (W/cos θ) or (Wsec θ).The frictional
force depends upon the normal force.Therefore; the effect of thread angle is to
increase the frictional force by a term (sec θ).This is because of the wedging action
of the threads. The coefficient of friction is taken as (μ sec θ) instead of μ in case of
trapezoidal threads and the equations derived for square threaded screw are
modified and used for trapezoidal or acme threads.
It has been found that the coefficient of friction (μ) at the thread surface
depends upon the workmanship in cutting the threads and on the type of the
lubricant. It is practically independent of the load, rubbing velocity or materials. An
average of 0.15 can be taken for the coefficient of friction, when the screw is
lubricated with mineral oil.
15
When the slenderness ratio is less than 30, there is no effect of buckling and
such components are designed on the basis of compressive stresses. Columns, with
slenderness ratio greater than 30 are designed on the basis of critical load. There
are two methods to calculate the critical load-Euler‟s equation and Johnson‟s
equation.
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CHAPTER 3
SCREW JACK
Jacks are used frequently in raising cars so that a tire can be changed. A
screw jack is commonly used with cars but is also used in many other ways,
including industrial machinery and even airplanes. They can be short, tall, fat, or
thin depending on the amount of pressure they will be under and the space that they
need to fit into. The jack is made out of various types of metal, but the screw itself
is generally made out of lead.
While screw jacks are designed purposely for raising and lowering loads,
they are not ideal for side loads, although some can withstand side loads depending
on the diameter and size of the lifting screw. Shock loads should also be avoided or
minimized. Some screw jacks are built with anti-backlash. The anti-backlash device
moderates the axial backlash in the lifting screw and nut assembly to a regulated
minimum.
A large amount of heat is generated in the screw jack and long lifts can cause
serious overheating. To retain the efficiency of the screw jack, it must be used under
ambient temperatures, otherwise lubricants must be applied. There are oil lubricants
intended to enhance the equipment‟s capabilities. Apart from proper maintenance,
to optimize the capability and usefulness of a screw jack it is imperative to employ
it according to its design and manufacturer‟s instruction. Ensure that you follow the
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speed, load capacity, temperature recommendation and other relevant factors for
application
3.2 Operation
The jack can be raised and lowered with a metal bar that is inserted into the
jack. The operator turns the bar with his hands in a clockwise direction. This turns
the screw inside the jack and makes it go up. The screw lifts the small metal
cylinder and platform that are above it. As the jack goes up, whatever is placed
above it will raise as well, once the jack makes contact. The bar is turned until the
jack is raised to the level needed. To lower the jack the bar is turned in the opposite
direction. An automatic screw jack has gears inside the jack that are connected to
the screw. Theses gears are connected by other gears and bars that are turned by a
power source to raise and lower the jack.
Although a jack is a simple and widely used device, the use of any lifting
device is subject to certain hazards. In screw-jack applications, the hazards are
dropping, tipping or slipping of machines or their parts during the operation. These
hazards may result in serious accidents. The main reasons of such accidents are as
follows:
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(iii)The centre of gravity of the load is off centre with respect to the axis of the jack
(iv) The screw-jack is not placed on hard and level surface.
(v) The screw-jack is used for a purpose, for which it is not designed.
Proper size, strength and stability are the essential requirements for the design of
the screw-jack from safety considerations.
Screw jack consists of a screw and a nut. The nut is fixed in a cast iron frame
and remains stationary. The rotation of the nut inside the frame is prevented by
pressing a set screw against it. The screw is rotated in the nut by means of a handle,
which passes through a hole in the head of the screw. The head carries a platform,
which supports the load and remains stationary while the screw is being rotated. A
washer is fixed to the other end of the screw inside the frame, which prevents the
screw to be completely turned out of the nut.
3.4 Function
3.5 Features
All jacks have safety features to protect the user from accidental injury. Wide
bases help to stabilize a jack and prevent tilting or sinking into soft soil. Most car
jacks also come equipped with their own handle or cranking mechanism, but
alternately many of these also will accept the flat end of a tire tool to jack up a
vehicle. When in the extended position, jacks will have a stop point that prevents
the user from overextending the jack beyond its rated capabilities. When in the
contracted position, jacks that are provided by the manufacturer will have a storage
area specially formed or designed for the jack to rest in when not in use.
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3.6 Benefits
Equipping motorists with car jacks has provided many benefits to those who
are on the road. Most importantly, jacks have equipped drivers with the ability to
change a tire in an emergency situation without having to call for assistance, which
can save service fees and potential towing fees as well. Car jacks also provide the
home auto enthusiast with a tool to use in maintenance of their own vehicle with the
simpler tasks such as changing brake pads, oil and belts. When used appropriately
with safety in mind, car jacks are an essential resource for anyone owning or
operating a motorized vehicle.
3.7 Types
Jacks are of mainly two types- mechanical and hydraulic. They vary in
size depending on the load that they are used to lift.
Scissors jacks are also mechanical and have been in use at least since the
1930s.
A scissor jack is operated simply by turning a small crank that is inserted into
one end of the scissor jack. This crank is usually "Z" shaped. The end fits into a ring
hole mounted on the end of the screw, which is the object of force on the scissor
jack. When this crank is turned, the screw turns, and this raises the jack. The screw
acts like a gear mechanism. It has teeth (the screw thread), which turn and move the
two arms, producing work. Just by turning this screw thread, the scissor jack can lift
a vehicle that is several thousand pounds.
Construction
A scissor jack has four main pieces of metal and two base ends. The four
metal pieces are all connected at the corners with a bolt that allows the corners to
swivel. A screw thread runs across this assembly and through the corners. As the
screw thread is turned, the jack arms travel across it and collapse or come together,
forming a straight line when closed. Then, moving back the other way, they raise
and come together. When opened, the four metal arms contract together, coming
together at the middle, raising the jack. When closed, the arms spread back apart
and the jack closes or flattens out again.
A scissor jack uses a simple theory of gears to get its power. As the screw
section is turned, two ends of the jack move closer together. Because the gears of
the screw are pushing up the arms, the amount of force being applied is multiplied.
It takes a very small amount of force to turn the crank handle, yet that action causes
the brace arms to slide across and together. As this happens the arms extend
upward. The car's gravitational weight is not enough to prevent the jack from
opening or to stop the screw from turning, since it is not applying force directly to
it. If you were to put pressure directly on the crank, or lean your weight against the
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crank, the person would not be able to turn it, even though your weight is a small
percentage of the cars.
Bottle jacks mainly consist of a screw, a nut, thrust bearings, and a body. A
stationary platform is attached to the top of the screw. This platform acts as a
support for the load and also assists it in lifting or lowering of the load. These jacks
are sturdier than the scissor jacks and can lift heavier loads.
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3.7.2 Hydraulic Jacks
Hydraulic jacks are typically used for shop work, rather than as an emergency
jack to be carried with the vehicle. Use of jacks not designed for a specific vehicle
requires more than the usual care in selecting ground conditions, the jacking point
on the vehicle, and to ensure stability when the jack is extended. Hydraulic jacks are
often used to lift elevators in low and medium rise buildings.
In a bottle jack the piston is vertical and directly supports a bearing pad that
contacts the object being lifted. With a single action piston the lift is somewhat less
than twice the collapsed height of the jack, making it suitable only for vehicles with
a relatively high clearance. For lifting structures such as houses the hydraulic
interconnection of multiple vertical jacks through valves enables the even
distribution of forces while enabling close control of the lift.
In a floor jack a horizontal piston pushes on the short end of a bellcrank, with
the long arm providing the vertical motion to a lifting pad, kept horizontal with a
horizontal linkage. Floor jacks usually include castors and wheels, allowing
compensation for the arc taken by the lifting pad. This mechanism provide a low
profile when collapsed, for easy maneuvering underneath the vehicle, while
allowing considerable extension
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3.8 Design of Screw Jack
The load on the screw is the load which is to be lifted W, twisting moment
M, between the screw threads and force F at the handle to rotate the screw.
The load W is compressive in nature and induces the compressive stress in the
screw. It may also lead the screw to buckle.
It is required to design a screw jack for supporting the machine parts during
their repair and maintenance. It should be a general purpose jack with a load
carrying capacity of 50KN and a maximum lifting height of 0.3m. The jack is to be
operated by means of a D.C motor.
(i) The frame of the screw jack has complex shape. It is subjected to
compressive stress. Grey cast iron is selected as the material for the frame.
Cast iron is cheap and it can be given any complex shape without
involving costly machining operations. Cast iron has higher compressive
strength compared with steel. Therefore, it is technically and economically
advantageous to use cast iron for the frame.
Fig:3.3 Screw
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(iii) There is a relative motion between the screw and the nut, which results in
friction. The friction causes wear at the contacting surfaces. When the
same material is used for these two components, the surfaces of both
components get worn out, requiring replacement. This is undesirable. The
size and shape of the screw make it costly compared with the nut. The
material used for the nut is stainless steel.
(i) The screw jack is an intermittently used device and wear of threads is not
an important consideration. Therefore, instead of trapezoidal threads, the
screw is provided with square threads. Square threads have higher
efficiency and provision can be made for self -locking arrangement.
When the condition of self-locking is fulfilled, the load itself will not turn
the screw and descend down, unless an effort in the reverse direction is
applied.
3.8.2 Thrust Bearings
Thrust ball bearings are used to replace the sliding force with rolling friction.
The friction torque is so small, that it can be neglected.
(ii)
Thrust ball bearing is suitable for a purely axial load. It is a single-direction
thrust ball bearing, because it can support axial load in one direction only, i.e.,
vertically downward. This ball bearing should not be subjected to radial load.
Single-direction thrust ball bearings are separable and the mounting is simple
as the components can be mounted individually. There are three separable parts of
this bearing known as shaft washer, a housing washer and the ball and cage
assembly. The mounting of thrust bearing I shown in the figure below
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Fig 3.4 Thrust Bearing
The inner diameter of the shaft washer is press fitted in the screw body. The
outer diameter of the housing washer is press fitted in the cup. These two
components are separately mounted before final assembly. The life of thrust bearing
is assumed to be 3000 hours.
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CHAPTER 4
Our survey in the regard in several automobile garages, revealed the facts that
mostly some difficult methods were adopted in lifting the vehicles for
reconditioning.
Now the project has mainly concentrated on this difficulty, and hence a
suitable device has been designed, such that the vehicle can be lifted from the floor
land without application of any impact force.
The fabrication part of it has been considered with almost case for its
simplicity and economy, such that this can be accommodated as one of the essential
tools on automobile garages.
4.1 Introduction
The motorized screw jack has been developed to cater to the needs of small
and medium automobile garages, which are normally man powered with minimum
skilled labor. In most of the garages the vehicles are lifted by using screw jack. This
needs high man power and skilled labour.
In order to avoid all such disadvantages, the motorized jack has been
designed in such a way that it can be used to lift the vehicle very smoothly without
any impact force. The operation is made simple so that even unskilled labour can
use it with ease.
The d.c motor is coupled with the screw jack by gear arrangement. The screw
jack shaft‟s rotation depends upon the rotation of D.C motor. This is a simple type
of automation project.
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4.2 Need for Automation
For mass production of the product, the machining operations decide the
sequence of machining. The machines designed for producing a particular product
are called transfer machines. The components must be moved automatically from
the bins to various machines sequentially and the final component can be placed
separately for packaging. Materials can also be repeatedly transferred from the
moving conveyors to the work place and vice versa.
28
a simple electromagnet by wrapping 100 loops of wire around a nail and connecting
it to a battery. The nail would become a magnet and have a North and South pole
while the battery is connected.
Now say that you take your nail electromagnet, run an axle through the
middle of it, and you suspended it in the middle of a horseshoe magnet as shown in
the figure below. If you were to attach a battery to the electromagnet so that the
North end of the nail appeared as shown, the basic law of magnetism tells you what
would happen: The North end of the electromagnet would be repelled from the
north end of the horseshoe magnet and attracted to the south end of the horseshoe
magnet.
The South end of the electromagnet would be repelled in a similar way. The
nail would move about half a turn and then stop in the position shown.
Torque in a motor
4.3.2.1 Introduction
In isolated systems away from the grid, batteries are used for storage of
excess solar energy which can be converted into electrical energy. In fact for small
units with output less than one kilowatt, batteries seem to be the only technically
and economically available storage means. Since both the photo-voltaic system and
batteries are high in capital costs, it is necessary that the overall system be
optimized with respect to available energy and local demand pattern.
29
(1) Low cost
(2) Long life
(3) High reliability
(4) High overall efficiency
(5) Low discharge
(6) Minimum maintenance
(A) Ampere hour efficiency
(B) Watt hour efficiency
Where high values of load current are necessary, the lead-acid cell is the type
most commonly used. The electrolyte is a dilute solution of sulfuric acid (H₂SO₄).
In the application motor is typically 200 to 400A. One cell has a nominal output of
2.1V, but lead-acid cells are often used in a series combination of three for a 6-V
battery and six for a 12-V battery.
The lead acid cell type is a secondary cell or storage cell, which can be
recharged. The charge and discharge cycle can be repeated many times to restore
the output voltage, as long as the cell is in good physical condition. However, heat
with excessive charge and discharge currents shortens the useful life to about 3 to 5
years for an automobile battery. Of the different types of secondary cells, the lead-
acid type has the highest output voltage, which allows fewer cells for a specified
battery voltage.
4.3.2.3 Construction
Sulfuric acid is a combination of hydrogen and sulfate ions. When the cell
discharges, lead peroxide from the positive electrode combines with hydrogen ions
to form water and with sulfate ions to form lead sulfate. Combining lead on the
negative plate with sulfate ions also produces sulfate. Therefore, the net result of
discharge is to produce more water, which dilutes the electrolyte, and to form lead
sulfate on the plates.
As the discharge continues, the sulfate fills the pores of the grids, retarding
circulation of acid in the active material. Lead sulfate is the powder often seen on
the outside terminals of old batteries. When the combination of weak electrolyte
and sulfating on the plate lowers the output of the battery, charging is necessary.
On charge, the external D.C. source reverses the current in the battery. The
reversed direction of flow of ions in the electrolyte results in a reversal of the
chemical reactions. Now the lead sulfates on the positive plate reacts with the water
and sulfate ions to produce lead peroxide and sulfuric acid. This action re-forms the
positive plates and makes the electrolyte stronger by adding sulfuric acid.
At the same time, charging enables the lead sulfate on the negative plate to
react with hydrogen ions; this also forms sulfuric acid while reforming lead on the
negative plate to react with hydrogen ions. It also results in formation of current
which can restore the cell to full output, with lead peroxide on the positive plates,
spongy lead on the negative plate, and the required concentration of sulfuric acid in
the electrolyte.
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On discharge, the pb and pbo₂ combine with the SO₄ ions at the left side of
the equation to formlead sulfate (pbSO₄) and water (H₂O) at the right side of the
equation.
Connected in series to get a voltage of 12V and the same 12V battery is
connected in series, to get an 24 V battery. They are placed in the water proof iron
casing box.
Always use extreme caution when handling batteries and electrolyte. Wear
gloves, goggles and old clothes. “Battery acid” will burn skin and eyes and destroy
cotton and wool clothing.
Check your batteries on a regular basis to be sure they are getting charged.
Use a hydrometer to check the specific gravity of your lead acid batteries. If
batteries are cycled very deeply and then recharged quickly, the specific gravity
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reading will be lower than it should be because the electrolyte at the top of the
battery may not have mixed with the “charged” electrolyte.
Check the electrolyte level in the wet-cell batteries at least four times a year
and top each cell with distilled water. Do not add water to discharged batteries.
Electrolyte is absorbed when batteries are discharged. If you add water at this time,
and then recharge the battery, electrolyte will overflow and make a mess.
Keep the top of your batteries clean and check that cables are tight. Do not
tighten or remove cables while charging or discharging. Any spark around batteries
can cause a hydrogen explosion inside, and ruin one of the cells.
On charge, with reverse current through the electrolyte, the chemical action is
reversed. Then the pb ions from the lead sulfate on the right side of the equation re -
form the lead and lead peroxide electrodes. Also the SO₄ ions combine with H₂ ions
from the water to produce more sulfuric acid at the left side of the equation.
As an example, a 200 A.h battery can supply a load current of 200/8 or 25A,
used on 8h discharge. The battery can supply less current for a longer time or more
current for a shorter time. Automobile batteries may be rated for “cold cranking
power”, which is related to the job of starting the engine. A typical rating is 450A
for 30s at a temperature of 0 degree F.
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The ratings for lead-acid batteries are given for a temperature range of 77 to
80ºF. Higher temperature increases the chemical reaction, but operation above
110ºF shortens the battery life.
Low temperatures reduce the current capacity and voltage output. The
ampere-hour capacity is reduced approximately 0.75% for each decreases of 1º F
below normal temperature rating. At 0ºF the available output is only 60 % of the
ampere-hour battery rating.
Measuring the specific gravity of the electrolyte generally checks the state of
discharge for a lead-acid cell. For instance, concentrated sulfuric acid is 1.835 times
as heavy as water for the same volume. Therefore, its specific gravity equals 1.835.
The specific gravity of water is 1, since it is the reference.
In a fully charged automotive cell, mixture of sulfuric acid and water results
in a specific gravity of 1.280 at room temperatures of 70 to 80ºF. As the cell
discharges, more water is formed, lowering the specific gravity. When it is down to
about 1.150, the cell is completely discharged.
The importance of the specific gravity can be seen from the fact that the
open-circuit voltage of the lead-acid cell is approximately equal to
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V =Specific gravity + 0.84
For the specific gravity of 1.280, the voltage is 1.280 = 0.84 = 2.12V, as an
example.
Note that the reversal of current is obtained just by connecting the battery VB
and charging source VG with + to + and –to. The charging current is reversed
because the battery effectively becomes a load resistance for VG when it higher
than VB. In this example, the net voltage available to produce charging currents is
15-12=3V.
Float charging refers to a method in which the charger and the battery are
always connected to each other for supplying current to the load. In figure the
charger provides current for the load and the current necessary to keep the battery
fully charged. The battery here is an auxiliary source for D.C. power.
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driven by a belt from the engine.When you start the car, the battery supplies the
cranking power. Once the engine is running, the alternator charges the battery. It is
not necessary for the car to be moving. A voltage regulator is used in this system to
maintain the output at approximately 13 to 15 V.It is a good idea to equalize charge
when some cells show a variation of 0.05 specific gravity from each other. With
proper care, lead-acid batteries will have a long service life and work very well in
almost any power system.
The screw jack used in this project is a 5 tonne bottle (cylindrical) jack. It
mainly consists of the body, screw, nut and thrust bearings. In this type of a jack,
the nut remains stationary while the screw rotates and helps in lifting or lowering of
the load.
The lead-acid battery is used to drive the d.c motor. The d.c motor shaft is
connected to the spur gear. If power is given to the D.c motor, it will run so that the
spur gear also runs to slow down the speed of the D.C motor. The screw jack moves
the screw upward, so that the vehicle lifts from ground.
The vehicle is lifted by using the lifting platform at the top of the screw jack.
The motor draws power supply from the battery. The lifting and uplifting is done by
changing the battery supply to the motor.
4.5 Advantages
2. Checking and cleaning are easy, because the main parts are screwed.
3. Handling is easy
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5. Easy to Repair.
4.6 Disadvantages
Care must be taken for the handling the equipment such as proper wiring
connection, battery charging checkup, etc.
4.7 Applications
1. It is useful in auto-garages.
2. This motorized screw jack is used for lifting the vehicles. Thus it can be
useful for the following types of vehicles in future;
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38
CHAPTER 5
DESIGN CALCULATIONS
= 50 x 103 N
= 50KN
For a 5 Ton capacity screw jack, the suitable screw is the one whose
nominal (major) diameter is 36mm.
Corresponding to the nominal diameter 36mm, the pitch (p) selected is 6mm.
The compressive stresses induced in lead screw due to load of 50KN is given by
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= (50 x 103 x 4)/ (π x 302)
= 70.73N/mm2
= 6/ (πx33)
= 0.057
θ = tan-1(0.14) = 7.96°
Ft = 16T/ (πdc3)
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= 31.01N/mm2
H = height of nut = n x p
The maximum length of the screw above the nut when lifting the
=706.85mm2
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L/K=slenderness ratio=100/7.5=13.33
Slenderness ratio is less than 30, therefore there is no effect of buckling and such
components are designed on the basis of compressive stresses.
The maximum value of the bending stress (or the permissible working
stress), at the section BC is given by
Fw = M.y / I
where
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h = Length of the tooth = 5mm
The quantity y is known as lewis form factor or tooth form factor and WT is called
the beam strength of the tooth. The value of y in terms of the number of teeth may
be expressed as follows:
y = 0.154
Where
The value of the velocity factor for very accurately cut and ground metallic
gears operating at velocities upto 20m/s is given by,
Cv =
C= 3.141m/s
v = 0.656
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FW = 196 x 0.656 = 128.576 N/mm2
WT = 128.576 x 25 x 16/30
WD=WT+WI
A deformation factor (C) depends upon the error in action between teeth,
the class of out of the gears, the tooth form and the material of the gears.
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CONCLUSION
Screw Jacks are the ideal product to push, pull, lift, lower and position loads
of anything from a couple of kilograms to hundreds of tonnes.The need has long
existed for an improved portable jack for automotive vehicles. It is highly desirable
that a jack become available that can be operated alternatively from inside the
vehicle or from a location of safety off the road on which the vehicle is located.
Such a jack should desirably be light enough and be compact enough so that it can
be stored in an automobile trunk, can be lifted up and carried by most adults to its
position of use, and yet be capable of lifting a wheel of a 4,000 -5,000 pound
vehicle off the ground. Further, it should be stable and easily controllable by a
switch so that jacking can be done from a position of safety. It should be easily
movable either to a position underneath the axle of the vehicle or some other
reinforced support surface designed to be engaged by a jack.
Thus, the product has been developed considering all the above requirements.
This particular design of the motorized screw jack will prove to be beneficial in
lifting and lowering of loads.
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BIBLIOGRAPHY
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