International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
Vol. 3 Issue 4, April - 2014

Design, Development and Modelling of Forklift

Ugale Sachin S.1, Salvi Tushar S.2, Lanjekar Sachin S.3, Kshirsagar Prashant R.4
1,2,3
Mechanical Engineering Department, Final Year Students RMCET, Ambav, Ratnagiri,India.
4
Assistant Professor, Mechanical Engineering Department, RMCET, Ambav, Ratnagiri,India.

Abstract- We describe the development of robotic forklift intended forks is assembled over the structure at front side. Since it
to operate alongside human personnel, handling palletized operates through a remote, it doesn‟t contain any steering
materials within existing, busy, semi-structured outdoor storage mechanism. The remote technology transfers the data by
facilities. The main objective of this project is to fabricate a RFID. All four motors are driven through a single „H‟ bridge
Mechanical forklift for material handling in industries. In this
DC motor drive package. All the four wheels are directly
paper a robotic vehicle is fabricated which runs to carry material
from one place to another by using Radio Frequency Technology. coupled to the motor shafts independently. The DC Motors are
Nowadays in industries, forklift used with hydraulic system. To having reduction mechanism, there by speed is reduced and
use forklift, it requires one spot guide to guide a forklift driver torque is increased.
because of less visibility. This paper discusses how to integrate
Radio frequency identification (RFID) technology into a forklift IV. WORKING
truck to make it wireless to increase visibility and human safety.
The mechanical system is considered as motion converter,
Keywords - RFID Technology, forklift trucks, visibility and human this can be created by implementing electro-mechanical
safety. techniques. The concept is to transform the motion from one
I. INTRODUCTION form to some other required form by using suitable
mechanical & electrical devices. In this research work the
A forklift is a vehicle similar to a small truck that has two technique of transform the rotational motion in to linear
metal forks on the front used to lift cargo. The forklift operator
motion is implemented. For this purpose five DC motors are
RT
drives the forklift forward until the forks push under the cargo,
used to create motion in the mechanism that functions as
and can then lift the cargo several feet in the air by operating
the forks.[1] forklift. These motors are constructed with reduction gear
mechanism & it is built in with the motor internally. As the
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Forklift is totally run on electric motors which are control machine is designed as prototype module, lowest rating
by a remote operator by means of remote will connected with motors are used to drive the mechanism.[8,9]
RFID which fix radio frequency transmit and receives to The name H-bridge sometimes called a "full bridge" is so
forklift circuits. [1,6,7]With electrical motor it gives the named because it has four switching elements at the "corners"
motion to the forklift vehicle like forward, back, left turn, right of the H and the motor forms the cross bar. If the bridge is
turn and pallet controlling up down motion, which are sufficiently powerful it will absorb that load and your batteries
controlled with remote and which will be transmitting signals will simply drain quickly.[1]
to receiver and receiver will convert signals to operation. It‟s
helpful to operator will be situated at only one position and it
will operate the forklift from one position and he we
monitoring on the neighbor environment due to that he will
avoid the accident and operate with vision cameras.[3,5]

II. FIELD OF USE

Electric forklift have got numerous applications. They are

used for transmission of materials from one place to another.
Forklifts and fork trucks are used to engage, lift, and transfer
palletized loads in warehousing, manufacturing, materials
handling, and construction applications.

III. LITERATURE SURVEY [14]

From the reference of the actual forklift named Landoll

we had scaled the actual dimensions to prototype model. The
mechanical structure of this prototype model is constructed
with metal plates, this structure looks like a rectangular
frame& the vertical moving mechanism that contains metal Fig. 1 Working Model

IJERTV3IS041632 www.ijert.org 1234

 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 3 Issue 4, April - 2014

= 31.50 𝑚𝑚 𝑠𝑒𝑐 𝑅2 + 𝑅4 = 78.32

Tangential force due to power transmission, 𝑅2 × 1.7 − 86.094 × 9.2 + 𝑅4 × 16.7 = 0
102 ×𝑃
𝑃𝑡1 = ∴ 𝑅2 = 34.39𝑁𝑅4 = 43.92𝑁
𝑉
102 × 1.71 × 10−3 1.7cm 7.5mm 7.5cm
= … … . 𝑃 𝑖𝑛 𝐾𝑊
31.50 × 10−3
= 5.53 Kgf = 55.37 N
Tension due to sagging of chain,
𝑃𝑠1 = 𝑘 × 𝑤 × 𝑎
= 2×0.12× 181.07 × 10−3 2 4P
t1
= 0.043𝐾𝑔𝑓 = 0.43𝑁 1 3 Pt3 PS3
K = coefficient of slag (for 𝜃 > 40° ) = 2 PS1 W
Fig. 2 Support Shaft layout
w =weight of chain
a =central distance 47.95 N 30.37 N

2. Design of lifting Chain and Sprocket:

Dia. of driving sprocket,

𝑝 34.39N 43.92 N
𝐷1 = 180
sin ⁡
( ) Fig. 3 Forces in vertical plane
𝑧1
6
= 180 = 49.77𝑚𝑚 4040.64 N-mm
sin ( )
26
Dia. of driven sprocket,
𝑝
𝐷2 = 180
sin ⁡
( )
𝑧2
6
= 180 = 25.07𝑚𝑚
sin ( ) 584N-mm
13
Centre distance between the sprocket should be between 30p 27.89 N Fig. 4 Bending Moment Diagram
to 50p,
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Assume a = 45p=45× 6 = 270𝑚𝑚

Calculation of no. of links in chain,

2𝑎 𝑧1 + 𝑧2 𝑧2− 𝑧1 2 𝑝
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31.062 N -3.162N
𝐿𝑛 = + +( ) ×
𝑝 2 2𝜋 𝑎 Fig. 5 Forces in horizontal plane
𝐿𝑛 =110 links
Exact center distance:
𝑝 𝑧 1 +𝑧 2 𝑧 1 +𝑧 2 𝑧 2 −𝑧 1 2
a= {[𝐿𝑛 − + [𝐿𝑛 − ]2 − 8
4 2 2 2𝜋
a=271.21mm 528 Nmm
Length of chain, Fig. 6 Bending Moment Diagram
L = 𝐿𝑛 × 𝑝 =110× 6 = 660𝑚𝑚 4040.64Nmm
Avg. velocity of chain,
𝜋𝐷 𝑁 𝜋×49.77×12 787.74Nmm
V= 1 1= = 31.27 𝑚𝑚 𝑠𝑒𝑐
60 60
Tangential force due to power transmission,
102 × 𝑃 102 × 1.71 × 10−3 Fig. 7 Resultant Bending Moment Diagram
𝑃𝑡3 = = … … . 𝑃 𝑖𝑛 𝐾𝑊
𝑉 31.27 × 10−3
=5.57Kgf = 55.7N
688.67 N-mm 688.67 N-mm
Tension due to sagging of chain,
𝑃𝑠3 = 𝑘 × 𝑤 × 𝑎
= 1×0.12× 271.27 × 10−3 = 0.032𝐾𝑔𝑓
= 0.324𝑁 Fig. 8 Torsional Moment Diagram
K = coefficient of slag (for 𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙) = 1
w =weight of chain Form fig. 4,
a =central distance Bending Moment,
𝑀1 =0
3. Design of shaft:[2,11,12,17] 𝑀2 = −34.39 × 1.7 = −58.4𝑁 𝑐𝑚
= −584𝑁 𝑚𝑚
Material: - 30C8; 𝑆𝑦𝑡 = 400𝑁 𝑚𝑚2 𝑀3 = 43.92 7.5 + 1.7 = 404.064𝑁 𝑐𝑚
From fig. 3, = 4040.6𝑁 𝑚𝑚
For vertical plane, 𝑀4 = 0

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