RAJALAKSHMI INSTITUTE OF TECHNOLOGY

KUTHAMBAKKAM, CHENNAI

FABRICATION OF MECHANICAL FORK LIFT USING REDUCTION GEAR MECHANISM

PROJECT MEMBERS : 23109114001 : G.AMIT KUMAR 23109114008 : P.BALAJI 23109114021 : T.HARIBABU 23109114039 : R.NIRMAL RAJ

SUPERVISOR Mr.J.SRINIVAS,M.E.,
ASSISTANT PROFESSOR MECHANICAL ENGINEERING

21-03-2013

OUTLINE OF THE PRESENTATION

OBJECTIVE TYPES OF FORKLIFTS PROJECT SCOPE PROCESS PLAN COMPONENT LEVEL DESCRIPTION WORKING CAD MODEL 2-D DIAGRAM COMPARISON DESIGN CALCULATION

BILL OF MATERIALS
ADVANTAGE & DIS-ADVANTAGES REFERENCES
21-03-2013

OBJECTIVE

The main objective in the project which we are going to implement the reduction gear mechanism to lift up the object with lower speed .

The forklift is operated by using motorized screw jack. To lower the speed and increase the torque we are using cluster gear mechanism.

21-03-2013

TYPES OF FORKLIFTS

Class I: Electric Motor Rider Trucks

Class II: Electric Motor Narrow Axle Trucks

Class III: Electric Motor Hand Trucks or Hand/Rider Trucks Class IV: Internal Combustion Engine Trucks (Solid/Cushion Tires) Class V: Internal Combustion Engine Trucks (Pneumatic Tires) Class VI: Electric and Internal Combustion Engine Tractors Class VII: Rough Terrain Forklift Trucks

21-03-2013

PROJECT SCOPE

From the title that has been given, the development of this project must include how to design the mechanical part of machine and how to fabricate the system of this mechanical part. It also needs some knowledge and skill to finish the project.

21-03-2013

PROCESS PLAN

PROBLEM DEFINITION

IDENTIFYING NEEDS OF PROBLEM

EVALUATING AND IDENTIFYING EXACT SOLUTION

EVALUATING EXISTING PRODUCTS

DEVELOPING MODEL

COMPONENT REQUIREME NT

DESIGN & CAD MODELING

EVALUATING DEVELOPED MODEL

ESTIMATION OF PERFORMANCE

21-03-2013

COMPONENT LEVEL DESCRIPTION

1. MOTOR HP , 1440 RPM 2NOS.

2. SCREW JACK

200 KG CAPACITY - 2NOS MATERIAL: BODY- CAST IRON LEAD SCREW MILD STEEL

21-03-2013

3. CLUSTER GEAR SPEED REDUCTION GEAR - 4NOS MATERIAL : MILD STEEL

4. MOUNTING SHAFTS

FOR MATING THE CLUSTER GEARS - 4NOS MATERIAL: MILDSTEEL

21-03-2013

4. FORK
USED FOR MATERIAL HANDELING. MATERIAL: MILD STEEL

5. FRAME A CASING USED TO HOUSE THE GEAR ARRANGEMENT MATERIAL : MILD STEEL

21-03-2013

WORKING

When the motor is switched on the power is transmitted from the motor sprocket to the two sets of cluster gears, in this way the speed of the motor is reduced. The output from the cluster gears is then given to the screw jack which is connected to the forks and raises upwards to lift the load.
21-03-2013
10

CAD MODEL

21-03-2013

11

ACTUAL MODEL

21-03-2013

12

2-D DIAGRAM

REDUCTION GEAR

SPUR GEAR

FORK
21-03-2013

FRAME
13

COMPARISON

S.NO

SPECIFICATION

MECHANICAL

HYDRAULIC

1.
2.

SIZE
MAINTAINANCE COST

COMPACT
LESS

BULKY
HIGH

3.

SELF-LOCKING FEATURE
WORKING ENVIRONMENT

PRESENT

ABSENT

4.

ANY TYPE

CONTROLLED ENVIRONMENT

21-03-2013

14

5. 6.

LOAD CAPACITY OVER ALL COST

5-75 TONS LESS

65-80 TONS HIGH

7.

OPERATING MEDIUM
SEALING

MANUAL OR ELECTRICAL

FRL UNIT

8.

ABSENT

PRESENT

21-03-2013

15

DESIGN CALCULATION

21-03-2013

16

21-03-2013

17

Design of spur gear

21-03-2013

18

21-03-2013

19

21-03-2013

20

FORK-LIFT CALCULATION

21-03-2013

21

21-03-2013

22

BILL OF MATERIAL

S.NO 1 2 3 4 5 6 7 8

COMPONENT FRAME (L-ANGLE) C- CHANNEL FORK (FLAT PLATE) MOTOR CLUSTER GEAR JACK GEAR MOUNTING SHAFTS MOTOR GEAR

MATERIAL MILD STEEL MILD STEEL MILD STEEL MILD STEEL MILD STEEL MILD STEEL MILD STEEL

COST 1300/350/520/3500/850/1200/580/85/-

9 10
11

SUPPORTING MEMBER SCREWJACK

MACHINING

MILD STEEL 21-03-2013

430/1400/4500/-

23

12 13

ARC WELDING MIG WELDING

1500/500/-

14 15
16

WHEELS FASTENERS
CONTROL SWTICH

420/410/280/-

TOTAL

17825/-

21-03-2013

24

ADVANTAGES AND DISADVANTAGES

ADVANTAGES: 1. RIGID 2. ON/OFF CONTROL 3. MECHANICAL ADVANTAGE 4. SELF LOCKING 5. LOW MAINTAINANCE AND OVERALL COST 6. SIMPLE IN MANUFACTURING AND CONSTRUCTION 7. USED IN ALL WORKING ENVIRONMENT

DISADVANTAGES: 1. HEIGHT LIMITATIONS 2. CANT GO UNDER OBSTRACLES LOWER THAN TRTRACTED LIFT 3. EFFICIENCY IS LOW

21-03-2013

25

REFERENCES

Design of machine elements by V.B.Bhandari

A text book of Machine Design by R.S.Khurmi,J.K.Gupta

PSG design data book http://en.wikipedia.org/wiki/Jack_(device) http://hubpages.com/hub/Automobile-Jacks http://www.powerjacks-de.com/Screw-Jacks-FAQ.html http://www.radicon.com/screw-jacks.php http://www.powerjacks.com/PowerJacks-History-The-Screw-Jack-Story.php http://www.scribd.com/doc/38577261/Screw-Jack-Design

21-03-2013

26

THANK YOU

21-03-2013

27