In today life there is wide of fork lifts variety of forklifts from the large

heavy loadings trucks to the one that works among narrow aisles forklifts have
becomes one of basics transportation tools we use in our lives with all the
forklifts in existence we find that there are some improvement that can be to
bring forklifts to the better performance.
Segway is a self-balancing transportation device with two wheel can
operate in any level pedestrian environment.
Existing forklifts design has its limitation in rotation and structures has
potential safety risk our new design as 90 degrees rotating forks attached to
truck body on both ends. also it has a scissor lift under the operator cabin which
improves the stability fork ;there is a total of 8 parts in the new design
Once the design is conceived, we calculate the mass properties of parts and
subassemblies to ensure the stability of the fork lift results show that truck is
safe to use its center of gravity remains in the safety triangle and we use this to
get the maximum loading capacity then we run stress analysis important parts
and subassemblies using finite elements Method (FEM) and their results show
that the new design is safe to use under working condition.

INTRODUCTION

The product varieties in different shapes and different packaging of goods

for loading and unloading has always been a heavy process during
transportation by fork lifts were naturally inverted and became the solution to
this problem they save time and space, if cargo’s are being organized properly
for the use of forklifts with right attachment would be a best way to load and
unload which would be make the whole process less time consuming the less
labors intensive in addition forklifts optimize the use of storage space by
eliminating the need for many people to handle the loading and unloading
operation and enabling the stacks up to good the stacking the height of goods
can be up 4-5m some even can be height as 10, which brings up the utilization
of warehouse by least 40% now most of the transportation operation are using
fork lifts.
Mechanization reduces the human efforts and manpower, but need to be
closer and complex human supervision. If consistency and close supervision is
not provided, there might be costly process error will occur. So, automation
process will eliminate the error and human interface by taking full control over
the operations of the mechanize equipment and provides a consistency through
the process control system and strong the instrumentation built in the system.

2 List of Parts

SR. NO. PART NAME NUMBER

1 GEARS(spur) 4

2 PINION(spur) 1

3 19mm SPANNER BOX 4

4 SHAFTS 4

5 Base plate or Base Rod 2

6 KEY 4

7. L Shaped anchore bolts 5

8. Cotter 4
 Table No.1.1 List of Parts

1.2 Objectives
In this project we investigate a forklift design that is new and different from
existing design. The new design offers two features:
1. The forklift attached to the frame body end.
2. The other feature is that the new lifting mechanism by lead screw where it is
easy to lift and more compact compare to the existing design.

The remainder of this thesis describes about more features and details. And also
we do analysis and calculation work on the model to make sure it is stable and
safe under different working condition.
1.3 Basic system of a forklift
Usually a fully functional forklift would consists of the following major system.
1. The power system,
2. Driving system,
3. Control system,
4. Loading system

But in our design we only concerned with the loading system, since we are not
going to focus on the power, driving and control system only we will give a
basic information in the following two sections the power system will be
included in the driving system.
LITERATURE REVIEW:

The first contribution toward scientific material handling instrumentality

seems to possess been the 2-wheel go-cart. during this we tend to square
measure move the fabric however not carry it. In 1906, a political candidate of
the Pennsylvania Railroad at Altoona, supplementary accumulator power to a
baggage wagon, it absolutely was the primary power truck. the primary
transportable elevator on record within the Patent and Trademark Office
Database was engineered of wood in 1867, with upright, cantilever platform,
and a hoist. One of the first efforts to mix horizontal and vertical motion was in
1887, once a crude truck capable of lifting its platform some inches was build.
This was most likely the primary application of the unit load principle with
skids. then in 1909, once the primary all steel carry truck appeared. In1913 a
truck appeared that supplementary wattage to advantage of combined vertical
and horizontal handling ability. It took a kind of tiny crane mounted on a
platform truck. The introduction of hydraulic power and therefore the
development of the primary electrical power self-propelled vehicle, beside the
utilization of standardized pallets within the late Nineteen Thirties. In 1954, a
British company named state capital Bagnall, currently a part of KION cluster,
developed what was claimed to be the primary slim aisle electrical reach truck.
throughout Fifties to Nineteen Sixties, operator safety became a priority because
of the increasing lifting heights and capacities. In our project, we tend to square
measure exploitation the battery power for the horizontal movement the vehicle
and therefore the human power to carry the fabric from the bottom. it's same
because the 1st self-propelled vehicle beside the battery power that was use in
1913 truck the easy mechanical mechanism for the lifting the fabric.

2.1 Burinskiene:"The Travelling of Forklift in Warehouse”.Retrieved

2008-01-22. After conducting an intensive literature review, it was found that
Extreme pressure is placed on all functions of traditional warehouse. The
warehouses have to be flexible and have possibility to increase or decrease its
operations in order to meet any demand. This has both advantages and
challenges. A key advantage is that warehouses are ready to underlay economic
trends and seasonality. A key challenge is that they have to stay competitive in
today’s market. This means that managers and engineers must continue to
improve the performance of their warehouse operations.

2.2 Brindley, James (December 2005). "The History of the Fork Lift".
Warehouse & Logistic News.Archived from the original on 2009-08-
31.Retrieved 2008-01-25. In 1906, the Pennsylvania Railroad introduced battery
powered platform trucks for moving luggage at their Altoona, Pennsylvania
train station. World War I saw the development of different types of material
handling equipment in the United Kingdom.

2.3 Dr.R.N.Mall (2013), Automated Guided Vehicle, ISBN 2091

Journal, MMMEC, Gorakhpur. In market there are several types of forklifts are
used in warehouses. These forklifts are either powered by gasoline, propane or
electricity but they are more difficult to maintain and fuel can be costly which
takes more space. To overcome this entire problem we designed and fabricate
the three wheel forklift which drives on electric power and loading & unloading
is done by hydraulic jack through forks. In general, there are a lot of activities in
traditional warehouses. Product typically arrives packed on a large scale and
leaves packed on a smaller scale. In other words, the most of products arrive in
pallets, but leave packed in cases; some very fast-moving products are received
in pallets and are shipped in pallets. In almost all supply chains, raw materials,
parts, and product inventories still need to be stored or buffered. In warehouses
products are received in pallets, placed to storage or pick locations, picked and
sent to customers. So, the material flow is based on following activities:
receiving, put-away, keeping in buffer, refilling (replenishment), picking and
shipping. The receiving activity includes the unloading of products from the
transport carrier, updating the inventory record, finding quantity or quality
inconsistency. Putaway involves the transfer of incoming pallets to storage
locations. Also put-away includes physical movements between different
functional areas. Pallet pick is considered as retrieval of pallet from storage
location to shipping doors. In our project, we tend to square measure
exploitation the battery power for the horizontal movement the vehicle and
therefore the human power to carry the cargo or packaged product from the
bottom.

2.4 Construction of Battery Operated Forklift, ISSN (online): 2349-784X,

IJSTE - International Journal of Science Technology & Engineering | Volume 2
| Issue 4 | October 2015 The mechanical structure of this prototype model is
constructed with metal plates, this structure looks like a rectangular frame& the
vertical moving mechanism that containsmetal forks is assembled over the
structure at front side. Since it operates through hydraulics, it contain cross four
bar steering mechanism. The DC Motors are having reduction mechanism, there
by speed is reduced and torque is increased.The mechanical system is
considered as motion converter, this can be created by implementing electro-
mechanical Techniques. The concept is to transform the motion from one form
to some other required form by using suitable mechanical & electrical devices.
In this research work the technique of transform the rotational motion in to
linear motion is implemented.

2.5 K , Design and Fabricated Pneumatic Operated Forklift, ISSN 2319-

5991, IJERST Vol. 4, No. 1, February 2015. Electric forklifts and hydraulic
forklift are great for warehouse use because they do not give off noxious fumes
like gas powered machines do. For this purpose a DC motors are used to create
motion in the mechanism that functions as forklift. The introduction of AC
powerforklifts, along with fuel cell technology, are also refinements in
continuing forklift development.

METHODOLOGY:

A fork elevate truck, conjointly referred to as a self-propelled vehicle and

alternative names, may be a battery-powered industrial truck. Its main purpose
is for material handling among facilities or compounds, particularly the
potential to elevate masses to be positioned at height also on lower them pro re
natal. Fitted with specific attachments, the fork elevate truck is also wonted to
perform alternative connected functions like the transfer masses from slip sheets
onto pallets, also on clamp them or to invert them. We are using the following
components.

a. Frame.
b. Pallet.
c. Wheel.
d. Bottle hydraulic jack.
e. DC motor.
f. Accelerator.
g. Battery.

The chassis is fictional from M.S sq. pipes. this can be finished easy
fabrication, and to scale back the weight. The chassis was designed to require a
static load of 3kg. The rear wheel that holds the motor and is fast to the chassis.
so, the driving motors will simply accommodate below the chassis. The chassis
incorporates hole for attaching front globe wheel, and for attaching the raise
structure. It’s an oblong plate that is command between 2 vertical channels of
M.S sq. pipe that area unit unengaged to slide up and right down to raise and
lower the weight/load up to a desired limit with the assistance of hydraulic
bottle jack that is operated on foot and it's placed between the fork. 3 wheels
area unit employed in self-propelled vehicle and the two wheels area unit placed
at front and the remaining wheel area unit placed at the rear. The hydraulic
device is employed for to raise the serious material by applying smaller force.
it's place at the front of the self-propelled vehicle. The hydraulic jack could be a
device used for lifting serious hundreds by the appliance of a lot of smaller
force. it's supported Pascal’s law, that states that intensity of pressure is
transmitted equally altogether directions through a mass of fluid at rest. D.C.
Motor is utilized in our project for moving fork carry from one location to a
special. Our project has only one motors wish to run the rear wheel. whereas the
lifting portion is completed by hydraulic jack & and it's connected to the
controller. The accelerator is employed for to keep up the speed of the self-
propelled vehicle. we tend to area unit mistreatment the accelerate of speed bike
connected to regulate controller. It provides power to motor. The battery is
placed at the rear aspect of frame .12volt battery issued to provide power.

CHAPTER-4

MATERIAL SELECTION

4.1 Introduction To Engineering Materials:

The selection of a material for a particular application is governed by the

working condition to which it will be subjected, ease of Manufacturing and the
cost considerations, pure metals find few applications in pure condition and
secondly they generally have poor strength in pure form. Various desired and
special properties can be achieved by addition of different material to form
alloys. Alloy comprises of a base metal and one or more alloying elements. The
typical properties associated with working condition are tenacity elasticity
toughness and hardness, toughness and typical properties associated with
manufacturing process is ductility, malleability and plasticity. The various
properties can be determined by testing techniques e.g. tensile test resistance to
abrasion by hardness test toughness by impact test and other special properties
like fatigue and creep test.

4.2 Engineering Material For Product Design:

All physical objects are made out of some material substance or other.
Mother Nature has her own set of building material for the objects of her
creation, living or non-living. Over the millennia, man has observed and
adapted many of these for making objects of his invention and design. For
engineering purposes, we now use a very wide spectrum of materials. These
generally fall under the following categories:-

 Materials as found in nature used after only very minor preparation such as
cutting to size, sun-drying, mixing with water. Some examples are coal,
wood and stones.
 Natural materials that are modified/ refined before use through some
physical, chemical or thermal processes that improve their utilization.
 Synthesized materials that are rarely found freely in nature. These are
derived from one or more natural raw materials through major
transformation processes. Most of the materials used in modern mechanical
engineering belong to this category.
4.3 Selection Criteria:
The designer selects the materials of construction for his product based
on several criteria such as its cost, the desirable properties that it should possess,
its availability, the preferred manufacturing processes that are to be employed,
etc. The overall economy is influenced by all these factors. In special cases,
essentiality and /or urgency of the need for the product can supersede the
economic considerations. The main criteria for material selection are discussed
below:
4.3.1 Cost Of The Material
The amount of raw materials, their composition, quality, any special heat-
treatment that is required, etc. influence the unit cost of materials. The unit cost
generally depends also on the quantity of raw material that is purchased in a
single lot. Special steel materials, for example, cost much more in the market
when purchased in small quantities from a retailer than in bulk directly from the
steel mill/stockyard.
4.3.2 Availability
The material should be readily available in adequate quantities. Material
availability is closely linked with the variety and level of technology obtained in
a given geographic location. Procuring materials from far and wide can be
expensive, due to the additional cost for transport, for transporter taxes and
duties etc.

4.3.3 Manufacturing Process

Facilities for shaping and treating the selected material into the finished
product or component must be available for economic production. Otherwise,
the production cost goes up. For example, the selection of forged alloy steel for
a connecting rod design necessarily assumes that a suitable forging facility is
available along with the necessary dies and other accessories. If the alloy is of a
rare quality, then facilities for its heat treatment might not be available.
4.3.4 Properties Of The Material
The desired function and performance of any product depends to a great
extent on the use of materials with the right physical and chemical properties. In
general mechanical engineering these properties can be classified into different
categories depending on how a particular property affects the function and life
of a component. The main property groups are:-
 Chemical Composition, specifying the contents of all the different
elements contained.
 Properties of state, such as solid, liquid or gas, density, porosity,
temperature.
 Strength related properties, such as ultimate strengths in tension,
compression and shear, yield strength/ 0.2% strength, fatigue strength,
notch sensitive, hardness, impact strength, effect of high/low
temperatures on strength, etc.
  Strain related properties, such as elongation at fracture, elastic moduli,
ductility, malleability etc. these help to ensure the desired rigidity/
elasticity, formability etc.
 Wear related properties, that determine the erosion, abrasion, friction
etc.., Between components in contact/ relative motion.

4.4 Selection Of Material

Carbon steel is an alloy of iron and carbon with varying quantities of
phosphorus and sulphur. To this alloy is added a deoxidizer to remove or
minimize the last traces of oxygen. Manganese is added to such an alloy to
neutralize sulphur, either alone are in combination with silicone or other
deoxidizers.
In carbon steel the maximum content of the following elements does not
exceeding the limits given against each:
Manganese ….. 1.65%

Silicone ….. 0.60%

Copper ….. 0.60%

The elements which are specified and are added into the carbon steel are carbon,
manganese, phosphorus, sulphur and silicon. The effect of these elements in
carbon steel is given below:
 CARBON contents are very important in determining the properties of steel.
The tensile strength of steel increases with increase in carbon contents up to
0.83% and beyond this it drops quickly. Hardness increases as the carbon
contents increases. Ductility and weld ability decreases with increase in
carbon contents.
 Manganese: Tensile strength and hardness increases with increase in
manganese content weld ability decreases by increase in manganese.
Manganese content in steel varies from 0.2 to 0.8%.
 Phosphorus: Tensile strength and hardness increases with increase in
phosphorus content. The phosphorus content in steel varies from 0.005 to
0.12% and maximum content permitted is 0.4%. In low phosphorus steel,
phosphorus steel, phosphorus is dissolved in matrix and in others it appears
as phosphate precipitate.
 Sulphur: Sulphur in steel lowers the toughness and transverse ductility,
Sulphur imparts brittleness to chips removed in machining operations. The
maximum permitted contents of sulphur in steel is 0.055%.
 Silicon: It is the principal deoxidizer used in the carbon steel Presence of
silicon in steel promotes increase of grain size and deep hardening
properties. Its addition is very useful in making steel adaptable for case
carburizing. Presence of the silicon varies from 0.1 to 0.35%.
 Copper: Though it is not an essential constituent of carbon steel yet it is
added up to 0.25% to increase the resistance to atmospheric corrosion.
The most important composition for carbon used as engineering material having
carbon % 0.02 to 0.30. Their merchantability is quite good. Such steel are used
in making small forging, crank pin, Gear, Valve, Crank shaft, railway axles,
cross head, connecting rods, rims for turbine gears, armature shafts and fish
plates.
4.4.1 Mild Steel

Plain carbon steel in which carbon contents ranges from 0.08 to below 0.3
are known as mild steel. Those mild steel in carbon contents is less than 0.15%
are known as dead mild steel. Mild steel are not such effected by heat treatment
processes, especially hardening process. A decrease in carbon content improves
the ductility of mild steel. These steels possess good machinability and
weldability. These are mainly used for making wires, rivets, nut, bolt, screw,
sheets, plates, tube, roads, shafts, structural steel section and for general
workshop purposes etc.

CHAPTER-5

DESIGN PROCEDURE

5.1 Design and Product Cycle

All engineering activities necessarily begin with some ideas with high or
low innovative content, translated into definite plans for their realization in the
form of products. This is the essence of design engineering. The ultimate
success depends on a thorough consideration of how the product will be made
and used as well as on the attention to detail paid by the design engineering.
This is applicable equally for a minor redesign of a existing product or for a
most innovative one. A good understanding of how the various phases of the
product cycle can influence the design is therefore Essential. The Product Cycle
can be better understood by fig. 5.1.

5.2 The Challenges Of Design Engineering

The present day industry bases economy is founded on the consumption of
as many different products as possible by as much number of users as possible.
It serves as an engine driving technology. The numbers put manufacturing
under pressure; the numbers as well as the variety put greater pressure on design
engineering. This is manifested by
 Short time available for design, development and testing of the product
before it reaches the user.
 Demands from the users for affordable cost combined with high quality of
performance and appearance.
 Increasing number of competition who can supply a product of equivalent
value. On one side, the scientific cooperation and exchange of information
have become international. On the other side, industrial activities and
communications network have become globalized. Given the present day
ease of access to technology, major break through in product innovation and
design are not really essential for industries to produce and prosper.

5.3 Qualities Of A Good Design

A good product design should satisfy the expectations of the customer/user.

These can be summarized in the following conditions. The product must

 Carry out the desired functions reliably.

 Appeal both technologically and psychologically.
 Be economical to acquire and to use.
 Be easy and safe to use.
 Be easy to maintain in working order.
In order to ensure the conditions, not only must the design concept be novel and
sound but the design must be well engineered. This engineering part of design
consists of
 Drawing up the main parameters for function and performance.
 Deciding the material, shape and dimensions of the components.
 Ensuring that the component dimensions satisfy the functional and strength
requirement.
 Ensuring the feasibility to manufacture or otherwise procure all the
necessary components, assemble them together and test them.
 Preparing the component and assembly drawing for guiding manufacture and
inspection.

EXPERIMENTAL SETUP

6.1. EQUIPMENT AND DRAWING COMPONENTS:

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. A fork lift one passes on the road may look like a fairly modern
invention, but these machines have actually been used for at least the past 2000
years, if not longer. The Romans used forklifts to build huge monuments.
Medieval churches were constructed with them. Also, the Egyptians may have
used them to create pyramids. The modern version can be either simple or
complex, and forklifts vary based on their application.
 Fig. 1

To make the project work more realistic, much importance is given for
practical orientation, therefore a prototype module is constructed for the
demonstration purpose. This module simulates the real working system & based
on this technology with slight changes in the structure & motor ratings, the
system can be converted for real applications. The method of converting rotary
to linear motion is implemented in the mechanism. The forklift is designed to
move in all directions including reverse direction also.
“Construction of Battery Operated Forklift” aims at eco-friendly and fuel
efficient and robust working with easy material handling and reducing the
number of accidents as it is remote operated. We also focused on reducing the
number of man power required during the loading and unloading operation of
forklift. Though it is remote operated not only the skilled labour but unskilled
labour can also operate as it does not require any special training. This forklift
will provide better visibility and thus reduces the number of accident and helps
in safe transportation to the destination.
Base (CHASIS):
The chassis is fabricated from Plywood sheet. This is done for ease of
fabrication, and to reduce the overall weight. The chassis was designed to take a
static load of 3kg. The flange which holds the motor was designed using
Aluminium and is bolted to the chassis. So that the driving motors can easily
accommodate below the chassis. The chassis incorporates hole for attaching
front globe wheel, and also for attaching the lift structure.
.
SLIDER: B
Its a rectangular plate which is held between two vertical channels of
Aluminium which are free to slide up and down to lift and lower the
weight/load up to a desired limit with the help of rope which is connected to the
DC Motor by means of Shaft and Bevel gears.
SHAFT: D.
A shaft is a rotating machine element which is used to transmit power from one
place to another. The power is delivered to the shaft by some tangential force
and the resultant torque set up with the shaft permits the power to be transmitted
to various machines linked up to the shaft. In order to transfer the power from
one shaft to another, the various members such as pulleys, gears etc are
mounted on it. These members along with the forces exerted upon them causes
the shaft tobending. In other words, we may say that a shaft is used for the
transmission of torque and bending moment. The various members are mounted
on the shaft by means of keys or splines.
PULLEYS: F.
The pulleys are used to transmit power from one point to another by means of
belts or ropes. Since the velocity ratio is the inverse ratio of the diameter of the
driving and driven pulleys, therefore the pulley diameter should be carefully
selected in order to have a desired velocity ratio. The pulley must be in perfect
alignment in order to allow the belt or rope to travel in a line normal to the
pulley faces. In our model we use plastic pulleys.
DC MOTOR: G.
An electric motor is a machine which converts electric energy into mechanical
energy. Its action is based on the principle that when a current carrying
conductor is placed in magnetic field, it experiences a mechanical force whose
direction is given Fleming’s Left Hand Rule.
BATTERY: H.
It supplies power to motor and gear box which runs the wheel and barrel. 12volt
battery isused to supply power.

Fabrication of Segway- prototype is consists of the following components

to full fill the requirements of complete operation of the machine.

1. DC motor
2. Battery
3. Bearing
4. Plat form
5. Handle
6. Rectifier
7. Step down transformer
8. Control unit

DC MOTOR

CHAPTER-7

MANUFACTURING PROCESS
Figure.1. diagram shoving centre of gravity of load, truck, and resultant
CG
The combined centre of gravity of the truck and load system shifts forward
outside the stability triangle, as the load's moment is greater than the vehicle's
moment, and the forklifttips forward, pivoting on the front axle or fulcrum.
Fig.2, The forklift teeters and finds its balance point.

Figure.2. stable and unstable forklift condition

The regular forklift are broad in size and can’t be utilized in narrow passages
with load as there are having more chases of accident as it’s quite difficult to
rotate n control in narrow passages whereas the two wheeler forklifts can be
utilized very easily in narrow passages as compared to regular forklift. Also, it’s
reduces the number of accident’s happening in handling, operating and working
in narrow space. The design features of forklifts is in many ways is at the heart
of many forklift related accidents. The intersection between the shifting centre
of gravity and the narrow track of the forklift, combined with the requirement to
handle loads at height can have detrimental effects on the vehicle’s stability.
Much of the problem lies is in the success of the operator maintaining the
forklifts centre of gravity within the triangle formed by the three suspension
points. “If the centre of gravity goes out of this area by lifting a load that is too
heavy, or by carrying a load too high and tilted forward, the forklift will tip
over”. (AMIC, 1999) As the topic suggests we need to design an forklift that
having low lifting capacity (below 90kilograms) and we cannot utilize regular
forklift’s as they aren’t convenient for this type of load as well as they consume
very high energy to perform task as compared to suggested two wheel forklift
for low weighted load therefore, we not only avoiding accidents in handling,
operation, travelling with load, stability, working in narrow space, but also its
efficient as it’s consume less power for required load. Forklifts have two groups
of controls, one for steering and one for lifting. The steering controls work
much like those of a golf cart. Though, dissimilar a car or golf cart, forklifts use
back wheel steering when you turn the steering wheel, the wheels on the rear
axle turn back and forth. This design is intentional, rear-wheel steering allows
the driver a larger degree of rotation and precision when control a load. The
lifting controls consist of two levers, one for lifting the fork up and down as
well as one for tilting the load back and forth. The lifting functionality works as
discussed above--forward moves up and backward moves down. The tilting
functionality, however, is slightly different. At the base of the masts are two sets
of additional hydraulic cylinders that attach to the base of the vehicle. When the
tilt- handle is moved forward, fluid is pumped into the chamber. This rise in
pressure pushes the piston head and causes the masts to lean away from the
vehicle's body. When the tilt-handle is moved back, fluid is slowly released
from this cylinder as fluid is pumped into the other pair of mast attached
cylinders. When the pistons from the latter pair push forward, the masts are
rocked back to the vehicle.

CURRENT FORKLIFT CHALLENGES There are three main areas that this
problems lies in Structure, while taking turn, disturbance in centre of gravity i.e.
balanced. Factories ,Warehouses , godowns having number of goods weighting
around 50-70 kilograms that are light in weight as compare to normal forklift
lifting capacity and can’t be moved by labors easily without any help . As the
possibility of accidents exist anywhere from the unbalancing of centre of
gravity to the crashes with any object in forklifts working route. Accordingly,
structure that withstand in the turning velocity of forklift during its fully loaded.
Despite, the wide range of applications are possible with forklifts mechanism.
The vehicle must first perfect in structure according to its possible uses. Current
forklift designs target to move loads above hundreds of kilograms however if
they necessary lifting capacity is reduce , a reduction in a number of required a
smaller structure and low power to drive forklift is possible, as the gap is
bridged between the maximum possible lifting capacity of single labor and the
forklift capacity. This would have direct advantages from the resulting
reductions in the overall vehicle weight and dimension, a lower energy is
required for the lifting loads of mass 40-70 kilograms and fewer systems that
must work succession reliably thereby increasing overall vehicle safety. The
focus on this project is to address this issue of reducing power consumption and
increasing efficiency of forklift having lifting capacity 40-70 kilograms.
PROBLEM DESCRIPTION & SCOPE OF CURRENT WORK A critical
path issue in forklift development is for two wheeler forklift operability to be
extended to lower lifting capacity and dimension specifically, two wheeler
forklift lifting capacity should be increase to 70 kilograms while maintains
performance at low lifting capacity within the same strength minimum variable
geometry features and the use of high torque low voltage operating motor.
Figure.3. forklift stability triangle

Factories, warehouses need forklifts and cranes for storage and moving large
goods. Also there are a number of goods weighing around 40 – 70 kilograms
that are comparatively lighter but cannot be moved around easily by single
labor. To full fill this need we have introduce a 2 wheel drive forklift to lift and
transport such medium weight goods across factories & industrial warehouses.
The 2 wheel drive is efficient and low power consumption vehicle that does not
require much space to carry load. The mini forklift will run on 2 dc motors and
can drive small weight with pickup across small distances easily. For this we
use a mini 2 wheel vehicle body frame made with a platform with 2 motorized
wheel mounts. It has a perpendicular handle ahead to hold take turns. Also we
design a forklift type mechanism on the front handle of vehicle using 2 bent
metal strips and lifting mechanism. The lift mechanism contains of large
rotating belt mechanism. This mechanism is connected with a high power and
high torque motor which used to lift loads on the forks. The further scope of
development in the following aspects, Structure: in the four wheel forklift the
structure is large due to its loading capacity must be high but in two wheel aisle
forklift, the lifting capacity is below 90 kilograms. The large forklifts above
capacity 150 kilograms can’t be utilized for loading such low weighted goods.
Due to energy wastage. So the two wheel aisles forklifts are the best in structure
as well as efficiency and power saving. Turning angle: four wheel forklifts can
take sharp turns up to 180 degree as they have balanced structure and safety
measures but in two wheel aisles forklift the sharp turns like 90 degree, 180
degree can’t be possible due to the rotational motion applied on the vehicle,
operator and the load. Which can results accidents Centre of gravity: in the large
forklifts the resultant centre of gravity due to vehicles centre of gravity and
centre of gravity of load is near to centre of gravity of vehicle and hence the
forklift is balanced and if the resultant centre of gravity is near to the centre of
gravity of load the forklift is unbalanced. And hence the accidents occurs, but in
two wheel the distance between centre of gravity of vehicle and balancing point
is less therefore it can perform specific task only.

Forklifts are powered by electric battery or combustion engines. Some Forklifts

allow the workers to sit while driving and operating the machine whereas others
require the worker to stand. It is being widely used during the industry for
moving materials and goods. Chassis are made from Mild Steel square rods and
mild steel metal sheet having space to stand an operator on board which inure
the chassis are strong enough to withstand the load. Also the chassis must have
enough space and arrangement to mount motors, battery, oil sump, forklift
arrangement, steering and operator on board. mast is mounted on front portion
of the chassis and battery is mounted on rear portion of it, for making insure the
resultant centre of gravity of empty vehicle is applicable on rare side of chassis.
We can also add the protective frame to insure security of on board operator if
needed, as in working in warehouses with narrow passage and high operation
height where accident can take place due to various causes. The wheels
mounted on below the chassis at the front portion. The wheel proposed are
pneumatic pressure rubber tire as they have nice grip on any floor whether it
having sloppy surface or rough surface. Also pneumatic tire can provide good
speed to the forklift and which required less power to driven after overcoming
the frictional resistance from surface. Also the emergency handbrake are
mounted over the wheels with control on steering in on board operator’s hand.
The handbrake is required to insure the safety of operator and avoiding any
accident which can cause financial loss, time loss, life loss, or can done damage
to the load or cargo which need to shift. Mast is mounted on chassis. Having
rectangular frame made of mild steel, square rods having good strength. It’s also
contain a high torque electric motor connected with teeth wheel connected with
various teeth wheel to insure strength of the motor does not reduce while lifting
load. The teeth wheel is connected with pinion and the rack arrangement is
provided on fork support which insure that the fork moves both direction up and
down as a required with its maximum lifting capacity. The hydraulic pistons are
attached to the two main horizontal structures known as masts. Forks that are
destined to carry the load are attached to the main body of the forklift by a set of
roller chain pulleys whose fulcrum forms a gear at the peak of the mast. Hence,
when the hydraulic pistons push the masts in ascending direction, the gears on
the masts is forced against the roller chains. It happens because the one side of
the chain is fixed to the permanent frame of the forklift, and the only way by
which masts can move ascending is when gears rotate in clockwise direction
and tug the forks above. The importance of this mechanism is that it let the
forks go far away from the range of the cylinders. If it is not meant for roller
chain pulleys then forklifts would need much larger cylinders to lift up the load
to a comparable height.

B
C

Figure.4. Rack and Pinion arrangement for driving of forklift shoving

various condition (a) moving forward or backward, (b) left turn (c) right
turn Steering is mounted over chassis to make comfortable to drive the forklift
with all control in operators hand than include a hand break control mounted on
steering. The steering provide good control over the forklift to avoid any loss
and damages while working in narrow passages. It having a small turning angel
so that operator can drive it comfortable even without much practice, the
steering is connected to a gear and that gear are in contact with another gear so
here we insure to avoid any shock to steering which can cause any accident
while driving. Further another gear is connected to the driving shaft with rack
and pinion arrangement over the driving shaft. Wheels are attached the high
torque low RPM Geared electric motor which are used to drive the forklift. The
motors are mounded horizontally bellow the chassis and wheels aligned to it
with the help of bevel gear which helps to transform the rotation motion of the
motor to the axis of wheel in 90 degree. Also the high torque motor which is
used in fork lifting mechanism is also transferring the rotational motion to gear
and further to chain with the use of bevel gear arrangement. The hydraulic
actuator is mounted on the chassis supporting mast and controlling the angle of
lifting fork to the ground. When the fork needed to load cargo over it the
hydraulic actuator get compressed and provide small if to the cargo so it’ll fit on
the lifting fork easily, also it’s helps in maintaining resultant centre of gravity
close to centre of gravity of vehicles to helps it in maintaining balance. And
when it needed to unload the lifting fork the hydraulic actuator get expanded
with operators control over it and helps in unloading the cargo to its destination.
WORKING PRINCIPLE
The wheel shaft is connected with arrangement of a motor. This motor is used
to run the vehicle. Battery is connected to the motor. The motor is connected to
the worm gear to increase the torque and is directly coupled to the wheel by
means of a bearing block which runs the vehicle. Motor is controlled by the
control unit. This vehicle causes no pollution. In front of the Segway the forklift
arrangement is mounted. The lead screw is used lift the fork and used to move
up and down.
The most important consideration of designing a fork lifts is the safety, while
the fork lifts is during the loading and moving stability system consists of 3
point of contacts ,2 front wheel drives and supporting the real wheel contact
axle arranged on safely mounted.

Counterweight - is a mass attached to the rear of the forklift truck frame. The
purpose of the counterweight is to counterbalance the load being lifted. In an
electric forklift the large lead-acid battery itself may serve as part of the
counterweight.
2) Power Source: Electric forklifts are powered by either a battery or fuel cells
that provides power to the electric motors. The electric motors used on a forklift
may be either DC or AC types.
3) Slider - is the vertical assembly that does the work of raising and lowering
the load. It is made up of interlocking rails that also provide lateral stability. The
interlocking rails may either have rollers or bushings as guides. It may be
mounted to the front axle or the frame of the forklift.
4) Switch: - 2 way switch
This switch is used in our project for selecting direction of fork lift.
5) Dc Motor:

D.C. Motor is used in our project for moving fork lift from one location to
another.
Our project has used three number of motors in which two motors are used to
run the rear wheels while one motor is used to run the barrel.

WORK ACTIVITIES OF FORKLIFT TRUCK

Forklift trucks are vehicles designed to move and stack heavy or bulky
goods. They are mainly used in warehouses, stockyards and other storage areas.
Forklift trucks are highly mobile with a very small turning circle which allows
them to move easily in confined spaces. On the front of the truck are two forks
operated by hydraulics. The driver must fit these forks into the pallets on which
goods are stored. The operator then uses the hydraulic forks to lift the pallet,
takes it to where it is needed and sets it down.
Some goods, such as bricks, can be moved by fork-lift trucks without the need
for pallets. They are stacked in bales with spaces for the forks. The operator
must work carefully as these goods are not protected by pallets. Some trucks are
fitted with small computer display panels that direct the operator where to place
goods in the warehouse.
Operators may also have to keep records and follow instructions written on a
worksheet. They are also responsible for the basic maintenance of the truck.
This includes greasing or oiling parts and changing or recharging the battery.
Forklift truck operators may have to work in a noisy and dusty environment.
Working outdoors in all weather conditions may also be necessary.
Industrial lift trucks are used for handling materials, parts, products, tools,
equipment, supplies and maintenance items. Forklifts are efficient for material
handling because they are self-propelled, maneuverable and require only one
operator to lift, transport, and stack or un-stack the material. Forklifts may be
used for indoor or outdoor use depending on their size, tyres and load
capacities. The major factors that lead to injuries involving the use of forklifts
include unsafe driving and material handling practices.
Although the term 'forklift', 'fork lift', or 'fork truck' is instantly
recognizable, their full, official title is a Fork Lift Truck, due to the fork shaped
tool at the front that traditionally was used to lift pallets. But now, like any other
piece of equipment, the forklift has evolved and is available in a wide variety of
styles, with varying functions and capacities, depending on where and how they
are to be used.
All lift truck operators must be trained prior to operating a lift truck.
Training is provided by the concern manufacturer and consists of both formal
instruction and practical training. Training is both vehicle- and workplace-
specific. The training is a one-time requirement unless the operator is involved
in a lift truck accident or is observed operating the truck in an unsafe manner.
Industrial lift trucks must be inspected prior to each day of service. A daily
inspection checklist must be completed and any defects should be reported and
corrected immediately. A truck may not be placed into service if any defects are
found during the inspection.
CHAPTER-8

ADVANTAGE 1. The loading and unloading process is easily done by this

machine 2. This machine is faster as compared to existing machine 3. This
machine is safe for worker during the material handling. 4. Easy to
maintenance. 5. Cost effective. 6. Easily Attachable & Detachable 7. Industrial
Goods Transport 8. Warehouse Internal Transport

ADVANTAGE 1. The loading and unloading process is easily done by this

machine 2. This machine is faster as compared to existing machine 3. This
machine is safe for worker during the material handling. 4. Easy to
maintenance. 5. Cost effective. 6. Easily Attachable & Detachable 7. Industrial
Goods Transport 8. Warehouse Internal Transport

CONCLUSION
The purpose of this paper was to focus on the solving problems at the
warehouses using forklift to carry load of lighter weight and making it efficient
n reduce the accident’s happening in warehouses due to large forklifts. The two
wheel aisle forklift is designed keeping the centre of idea to increase work
efficiency, reducing power Consumption, smaller dimension and hence aisle for
movement in narrow space of warehouses, high safety factor, time saving
application, easy controlling from on board. At the closing of this report, it is
evident that there are important areas which call for future research and
analysis. The first of this is that completely autonomous working without any
human assessment. This will enable more productivity and high reliability.
Additionally, method of lifting forklift can be changed safety measures, power
consumption can be reduced. For the next step in the design of this particular
forklift, higher fidelity analysis method should be employed to ensure that
lifting mechanism would to interesting and provide direction towards the
application of this forklift.

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