A Project Report On

4 WHEEL FORKLIFT BY PEDAL OPERATED

Submitted to

STATE BOARD OF TECHNICAL EDUCATION AND TRAINING

In partial fulfillment of the requirement of the award of degree of

DIPLOMA

IN

MECHANICAL ENGINEERING

By

A.LOKESH VEERA BALAJI 17233-M-002

M.SAGAR 17233-M-030

M.SUMAN 17233-M-031

N.AKHIL 17233-M-048
Under the guidance of

Mr. A. NARAYANA MURTHY

Assistant Professor

Mechanical Department

DEPARTMENT OF MECHANICAL ENGINEERING

MAHAVEER INSTITUTE OF SCIENCE & TECHNOLOGY

POLYTECHNIC
Approved by AICTE , affiliated to SBTET-Hyderabad, vyasapuri , Bandlaguda , POST

Keshavgiri (p.0), Hyderabad-500005

2019-2020
 CERTIFICATE
This is to certify that the project work entitled "4 WHEEL FORKLIFT BY
PEDAL OPERATED” is submitted by, A.LOKESH VEERA BALAJI,
M.SAGAR, M.SUMAN, N.AKHIL in partial fulfillment of the requirements for the
award of the Degree of Diploma in MECHANICAL ENGINEERING from

MAHAVEER INSTITUTE OF SCIENCE & TECHNOLOGY, during the

academic year 2019-2020.

The result embodies in the project report have not been submitted to any other
university or institute for the award of any degree.

To the state Board of Technical Education and Training as a record bonafide work done by
them under our supervision and guidance.

Mr.A.NARAYANA MURTHY Dr. S. MURALI

Assistant Professor Head of the departmant

(Project Guide)

P.RAMESH
EXTERNAL EXAMINER PRINCIPAL
 ACKNOWLEDGEMENT
This project works carried out at Mahaveer Institute of Science and Technology,
Hyderabad, as a part of our academic requirements for obtaining the Diploma degree was a wonderful
experience. We take this opportunity to thank all the people who was motivated and helped us to
complete the project successfully.

We would like to thank our guide Mr. A. NARAYANA MURTHY, Asst.professor,

Department of Mechanical Engineering, for his valuable guidance and support.

We would like to express our sincere gratitude to our Head of Department

Dr.S.MURALI, Mechanical Engineering and our principal Mr.P.RAMESH , Mahaveer
institute of Science and Technology for granting us permission to carry out our project. We are also
thankful to the Mechanical Engineering department.

We would like to thank all our teaching and non-teaching staff who directly and indirectly
helped our project.

We are a great thanks to our parents, relatives and friends for their wholehearted support
and encouragement towards fulfilment of the degree.

A.LOKESH VEERA BALAJI 17233-M-002

M.SAGAR 17233-M-030

M.SUMAN 17233-M-031

N.AKHIL 17233-M-048
 DECLARATION

We hereby declare that the project report entitled “4 WHEEL FORKLIFT BY

PEDAL OPERATED” under the guidance of Mr. A.NARAYANA MURTHY,

Asst.Professor , Department of Mechanical Engineering,MAHAVEER INSTITUTE OF

SCIENCE & TECHNOLOGY is submitted in partial fulfilment of the requirements for the
award of the degree of Diploma in MECHANICAL ENGINEERING.

This the record of bonafide work carried out by us and the result embodies in this project have not
been reproduced or copied from any source. The result embodies in this project have not been
submitted to any other university for the award of any other degree.

A.LOKESH VEERA BALAJI 17233-M-002

M.SAGAR 17233-M-030

M.SUMAN 17233-M-031

N.AKHIL 17233-M-048
 ABSTRACT

THE MECHANICAL FIELD IS IMPROVING DAY BY DAY. LOTS OF INNOVATIE IDEAS ARE
ENTERING INTO THE FILED. THIS PORJECT REPORT IS INDEED TO ENDOW WITH A
COMPREHENSIVE STUDY OF THE TECHNICAL AND THEORETICAL ASPECTS OF “4 WHEEL
FORKLIFT BY PEDAL OPERATION” ALL THE TOPICS COVERED IN THS REPORT ARE
ESSENTIAL FOR THE COMPLETE UNDERSTANDING AND SURVEY OF THE TITTLE “4 WHEEL
FORKLIFT BY PEDAL OPERATED”.

THIS REPORT ENGROSSES DIFFERENT CHAPTER AND EACH IS DESIGN IN THE ORGANIZED
STYLE.

i.
 LIST OF CONTENT
PAGE NO

CHAPTER 1 INTRODUCTION 1

1.1 4 WHEEL FORKLIFT BY PEDAL OPERATED 2

CHAPTER 2 LITERATURE SURVEY 4

2.1 4 WHEEL FORKLIFT BY PEDAL OPERATED 5

CHAPTER 3 DESCRIPTION OF COMPONENTS 6

3.1 FORKLIFT

3.1.1 TYPES OF FORKLIFT 7

3.2 SPROKETS 8

3.2.1 TYPES OF SPROCKETS 9

3.3 CHAIN DRIVE 10

3.3.1 TYPES OF CHAIN DRIVE 11

3.4 WHEELS 13

3.4.1 TYPES OF WHEELS

3.5 DC MOTOR

3.5.1 TYPES OF DC MOTOR

3.6 BEARING

3.6.1 TYPES OF BEARINGS

3.7 BATTERY

3.8 FRAME

3.9 SHAFT

3.10 BOLTS, NUTS, AND WASHERS

CHAPTER 4 DESIGN AND ESTIMATION 14

4.1 DESIGN CALCULATION 15

4.2 ESTIMATION 19
 4.3 WORKING PRINCIPLE 21

CHAPTER 5 ADVANTAGES, DISADVANTAGES & APPLICATION 33

6.1 ADVANTAGES 34

6.2 DISADVANTAGES 34

6.3 APPLICATONS 34

CHAPTER 6 CONCLUSION 34

CHAPTER 7 REFERENCES 34
CHAPTER-1

1
 INTRODUCTION
In general the forklift can be defined as a tool capable of lifting hundreds of kilograms. A forklift is a
vehicle similar to a small truck that has two metal fork on the front used to lift cargo. The forklift operator
drives the forklift forward until the fork push under the cargo , and can then lift the cargo several feet in the air
by operating the fork. The forks, also known as blades or tines , are usually made out of steel and can lift up to
a few tons.

Forklift are either powered by gasoline , propane , or electricity. Electric forklifts relay on batteries to
operate. Gasoline or propane forklift are sometimes stronger or faster than electric forklifts, but they are more
difficult to maintain, and fuel can be costly. Electric forklifts are great for warehouse use because they do not
give noxious fumes like gas powered machines do.

The mechanical structure of this prototype module is constructed with square L- Angular rods, this
structure looks like a rectangular box & the vertical moving mechanism that contains metal forks is assembled
over the structure at front side. Since it operates through a switch ,it doesn’t contain any steering mechanism.
The entire vehicle is designed to through four wheel, & pedal operation is used to drive al four wheels directly.
One side the shaft is connected to the cycle chain sprocket which has locked to run for booth front and back
ward directions.

1.1 4 WHEEL FORKLIFT BY PEDAL OPERATED

In general the conventional system, during loading or unloading at depots, the operator is required to be
stationed inside the drive’s cabin to operate the forklift movement Just like many other inventions, the forklift
was born out of necessity. The four-wheel hand operated forklift first works on the pedal operation for
movement purpose and a motor used to load and unload the components by the use of electrical power to
reduce the natural resources usage .this vehicle is designed for a loading and unloading small loads. The
module simulates the real working system & based on the technology with slight changes in the structure &
motor rating, the system can be converted for real applications. The method of converting rotary to linear
motion is implementing in the mechanism. The forklift is designed to movie in front and reverse directions
only and can lift the load and move them to certain places.

2
As this development work falls under the subject of Mechatronics, various fields of technologies must be
included to full-fill the target. The purpose of mechatronics is to provide knowledge regarding the Mechanical,
Electrical, Electronics, Embedded Software, and Digital components required for the system. 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 mini module simulates the real working system & based on
this technology huge machine can be constructed for real applications. The machine is constructed with
electronics, electrical & mechanical components. The mechanical structure is constructed with a variety of
devices as they relate to robots. The method of converting rotary to linear motion is implemented in the
mechanism, for this reason three DC motors with reduction gear mechanism are used to create motion in the
mechanism in three dimensions.

3
CHAPTER-2

4
 LITERATURE SURVEY

2.1 4 WHEEL FORK LIFT BY PEDAL OPERATED

In general the conventional system, during loading or unloading at depots, the operator is required
to be stationed inside the drive’s cabin to operate the forklift movement Just like many other
inventions, the forklift was born out of necessity. The two-wheel hand operated forklift first appeared

over one hundred years ago. These original units were wrought-iron axle and cast iron wheels which
enabled loads to be lifted and transported without manual labor. In the early 1900s the evolution to
combine horizontal and vertical motion resulted in the first hand operated forklift capable of lifting a
few inches of the ground. And with this the development of the forklift are on fastrack till today.

In 1917 the Clark Company, manufacturers of axles, created a truck called the Tructractor to move
materials around their factory. As people visited the factory and saw the Tructractor at work they
placed orders from Clark to build Tructractors for their companies. A few years later the first
hydraulic powered lift was added to some trucks to give them lifting power. In 1923, Yale was the
first company to use forks that lifted loads off the ground and an elevated mast that could extend
beyond the height of the truck. The Yale truck is considered to be the first forklift. A few
developments helped the forklift to increase in production including the introduction of the
standardized pallet in 1930 and World War II. Both of these developments increased production of
forklifts and allowed distributors the means to efficiently move heavy loads.

5
CHAPTER-3

6
 DESCRIPTION OF COMPONENT

3.1 LIST OF COMPONENTS

The main components used to fabricate the model are

1 Forklift

2 Sprocket

3 Chain drive

4 Wheel

5 DC motor

6 Bearing

7 Battery

8 Frame

9 Iron pipe

10 Bolts, nuts and washers

7
 3.1.FORKLIFT
Electric forklifts are great for warehouse use because they do not give off noxious fumes like gas powered
machines do. Forklifts are most often used in warehouses, but some are meant to be used outdoors. The vast
majority of rough terrain forklifts operate on gasoline, but some use diesel or natural gas. Rough terrain forklifts
have the highest lifting capacity of all forklifts and heavy duty tires (like those found on trucks), making it possible
to drive them on uneven surfaces. Forklifts have revolutionized warehouse work. They made it possible for one
person to move thousands of pounds at once. Well-maintained and safely operated forklifts make lifting and
transporting cargo infinitely easier. This is the general description of a normal forklift.

3.1.1TYPES OF FORKLIFT

1. 3 or 4 wheel forklift truck

* Three wheel forklift trucks are used for indoor and warehouses were space requirement is very
important.

* While four-wheel forklift trucks are used for lifting heavy loads in outdoor uses and transportation
at long distances.

* Used for loading trucks and moving pallets and other loads.

* It may be electric, diesel or gasoline operated.

* Diesel and gasoline powered forklifts will generate more power than electric lifts and move faster
over long distances.

* Capacity ranging from 3 ton- 40 ton.

8
 2. Reach trucks/ Narrow-Aisle forklift

* Perfect for optimizing storage space use.

* Use to rack pallets on smooth surfaces.

* Are generally electric powered.

* Very much useful at small passages in warehouses and small industries.

* Can lift heights upto 10 meters.

* Ranging from 1-3 tons load lifting capacity.

3. Order-pickers/ Stock-pickers

*Use for rider to stand on an elevating platform along with forks so rider may rise to select the
materials.

9
 * Very much useful for packaging industries and warehouses were they are constantly required to
pick and put heavy packages at certain level.

* Used in very narrow paths.

* Generally electric powered.

* Capacity ranging from 1-3 ton.

4. Turret trucks type forklift

* In this type of forklift, Forks are mounted on a mast and carriage that operates on a turret able to
rotate at 90 degrees in either direction for picking the loads without turning the base of the forklift.

* Use in very narrow aisles and employ a rotating mast.

* Generally electric powered.

* Capacity of lifting load is from 1.5- 4 ton.

10
 5. Rough Terrain Forklifts

* Rough terrain forklifts are used for outdoor works where uneven surface conditions needs to be
faced.

* It is an one type of heavy capacity forklift widely used for engineering and construction purposes.

* It is generally gasoline, diesel or CNG operated.

* Load capacity is 15 ton or more according to size and operations.

* Ideal for lumberyards, construction projects, landscaping and other outdoor uses.

6. Hydraulic Fork Lift or Pallet truck

* Hydraulic forklift is the most compact design from the overall forklift family.

* It is widely use in all types of industry where indoor material transportation are essential .

11
 3.2. SPROKETS
A sprocket is a profiled wheel with teeth, cogs, or even sprockets that mesh with a chain. The sprockets are
used for the power transmission between steering and wheel through the roller chain drive. A sprocket is a profiled
wheel with teeth that meshes with a chain, track or other perforated or indented material. Chain sprocket is a part
this vehicle. Chain sprocket are used to provide the clockwise or anticlockwise direction to front wheel and rear
wheel through the chain drive. Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, and other
machinery either to transmit rotary motion between two shafts where gears are unsuitable or to impart linear motion
to a track, tape etc.

Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, and other machinery either to transmit
rotary motion between two shafts where gears are unsuitable or to impart linear motion to a track, tape etc
 12

3.2.1Types of sprockets

* Double pitch sprockets. (similar to standard sprockets except there are half the number of teeth

* Multiple strand sprockets.

* QD ( Quick Disconnect) sprockets.

* Taper-Lock sprockets.

* Steel split sprockets.

* Ouble single sprockets.

* Idler sprockets.

3.3. CHAIN DRIVE

A roller chain is the type of chain driven most commonly used for transmission of mechanical power between
two sprockets. It consist of a series of short cylindrical rollers held together by side links. It is driven by a toothed
wheel called a sprocket.It is often used to convey power to the wheels of a vehicle, particularly bicycles and
motorcycles. It is also used in a wide variety of machines besides vehicles. In this vehicle first chain drive
connected with sprocket of front wheel and sprocket of steering and second chain drive is connected with sprocket
of rear wheel
 13

Chain drive is a way of transmitting mechanical power from one place to another. It is often used to convey
power to the wheels of a vehicle, particularly bicycles and motorcycles.

In other situations, a second gear is placed and the power is recovered by attaching shafts or hubs to this gear

3.3.1Types of chains used for mechanical transmission are :

They are six styles of chain used for mechanical transmissions are

* Roller chain

* Detachable chain

* Pintle chain

* Silent chain

* Leaf chain

* Laminated metal chain

3.4 WHEELS
In this vehicle wheels are made of steel and rubber material. Wheel are connect with ms round rod Rotate by
help of chain sprocket, chain drive and bearing arrangement. The front wheel rotates ideal and chain driver
arrangement
 14

The wheels thus brought mobility to our daily life. All the modes of our daily transportation such as car,
bicycle, scooter, train and even airplane needs wheel. The airplane cannot take off without wheel. The wheel
functions as a turbine in engines and machines to lend them mechanical advantage

3.4.1The different types of wheels are

 Forged steel. Fine grain forged steel wheels are precision machined to offer the greatest load capacit,
impact strength and rollability.
 Cast iron.
 Ductile Iron.
 Polyurethane.
 Mold On Rubber.
 Ny Tec-MD.
 Phenolic Resin.
 V-Grove.

3. 5 DC MOTOR

In this vehicle one DC motor are provide in each wheel to move forward and backward direction. The
specification of motor used is 12 V, with 60 rpm.When power supply from battery to DC motor then DC
motor rotate in clockwise direction and when reverse current supply from battery to DC motor then Dc
motor will anticlockwise direction. Which will forward and backward movement of vehicle. An electric
motor uses electrical energy to produce mechanical energy. In any electric motor, operation is based on
simple electromagnetism. A current-carrying conductor generates a magnetic field; when this is then
placed in an external magnetic field, it will experience a force proportional to the current in the conductor,
and to the strength of the external magnetic field. As you are well aware of from playing with magnets as a
kid, opposite (North and South) polarities attract, while like polarities (North and North, South and South)
repel. The internal configuration of a DC motor is designed to harness the magnetic interaction between a
current-carrying conductor and an external magnetic field to generate rotational motion.

15

A Dc motor or direct current motor converts electrical energy into mechanical energy. A direct battery use
A Dc motor is any of a class of rotary electrical machines that converts direct current electrical energy into
mechanical energy. The most common types rely on the forces produced by magnetic fields. Nearly all
types of dc motors have some internal mechanism, Either electromechanical or electronic, to periodically
change the direction of current flow in part of the motor

DC motors were the first form of motor widely used, As they could be powered from existing direct-
current lighting power distribution systems. A DC motor’s speed can be controlled over a wide range,
using either a variable supply voltage or by changing the strength of current in its field windings. Small dc
motors are used in tools, toys, and appliances. The universal motor can operate on direct current but is a
 lightweight brushed motor used for portable power tools and appliances. Large dc motors are currently
used in propulsion of electric vehicles, elevator and hoists, and in drives for steel rolling mills. The advent
of power electronics has made replacement of dc motors with ac motors possible in many applications.

3.5.1 Types of DC motor Includes

* Permanent magnet dc motor (pmdc motor)
* Separately excited dc motor
* Self Excited dc motor
* Shunt Wound dc motor
* Series wound dc motor
* Compound wound dc motor
* Short sunt dc motor.
* Long shunt dc motor
16

3.6. BEARINGS

In this vehicle bearing is use easy to move wheel from one direction to other direction, each
bearing is connected with each wheel with the help of sprocket and iron pipe.A bearing is a machine
element that constrains relative motion to only the desired motion, and reduces friction between
moving parts. The design of the bearing may, for example, provide for free linear movement of the
moving part or for free rotation around a fixed axis; or, it may prevent a motion by controlling the
vectors of normal forces that bear on the moving parts. Most bearings facilitate the desired motion by
minimizing friction.
 A bearing is a machine element that constrains relative movement to the desired motion and
reduces friction between moving parts

3.6.1Types Of Bearings

1. Ball Bearings

2. Roller Bearings

1. Ball bearings

Ball bearings utilize balls as the rolling elements. They are characterized by point contact
between the balls and the raceways. As a rule, ball bearings rotate very quickly but cannot support
substantial loads.

17

a. Deep-Groove Ball Bearings

The most commonly used bearings are deep-groove ball bearings. Thanks to their simple design,
they are easy to maintain and not as sensitive to operating conditions thus are used in a wide range of
different applications. In addition to radial forces, they absorb axial forces in both directions, Their
low torque also makes them suitable for high speeds

b. Angular Contact Ball Bearing

Angular contact ball bearings are characterized by a contact angle, This means the force are
transferred from one raceway to the other at a particular angle. Angular-contact ball bearings are
therefore suitable for combined loads, where high axial forces have to be transferred in addition to
radial forces.

c. Self- Aligning Ball Bearings

Self-aligning ball bearings include a double row of balls guided by a cage and double row inner
ring raceway but have the special feature of a continuous spherical outer ring arceway allowing the
inner ring/ball complement to swivel within the outer ring, This is what enables a degree of self-
alignment in the application. This type of bearing is recommended when alignment of the shaft and
the housing are the problem and the shaft could deflect. Self aligning ball bearings are most suitable
for absorbing radial forces.
 d. Thrust Ball Bearings

Thrust ball bearings consist of two bearing discs with raceways for the balls. Thrust ball bearings
were developed solely for absorbing axial forces in one direction, meaning they can locate the shaft
axially in one direction.

2. Roller Bearings

Roller Bearings are characterized by line contact. Line contact offers higher load rating than ball
bearings of the same size; however the speed ability is lower than a ball bearing due to the increased
friction of a contact line.

18

a. Spherical Roller Bearings

Spherical Roller Bearings are very robust and work on the same principle as self aligning

bearings with the exception that they use spherical rollers instead of ball rollers allowing

higher loads to be supported. This can compensate for misalignments between the shafts

and the housing. Spherical roller bearings are suitable for absorbing high radial loads and

moderate axial loads.

 b. Cylindrical Roller Bearings

Cylindrical Roller Bearings use line contact between the rolling elements and the raceways,
which optimizes the distribution of stress factors at the point of contact. This arrangement means that
cylindrical roller bearings have a very high radial load rating. Depending on the design, they may also
be able to transmit limited amounts of axial loads.

c. Tapered Roller Bearings

Tapered Roller Bearings have tapered raceway in the inner and outer rings with conical rollers
arranged between them. Due to the contact angle, tapered roller bearings can absorb high radial and
axial forces in one direction. Tapered roller bearings are often combined in pairs to support axial
forces in both directions.

19

d. Needle Roller Bearings

Needle Roller Bearings are special type of cylindrical roller bearing which contain long, thin
rolling elements, known as needle roller. The ratio of diameter to length is between 1:3 and 1:10.
Needle roller bearings have a high load rating and are only suitable for radial forces. If space is
constricted, needle bearings can be a god solution.
 3.7 BATTERY

Battery is one of the important parts of 360 degree wheel rotation vehicle. Which is connected to DC
motor by electric wire. It is store electrical energy and supply to DC motor so vehicle will move forward
and backward direction. Batteries operate by converting chemical energy into electrical energy through
electrochemical discharge reactions. Batteries are composed of one or more cells, each containing a
positive electrode, negative electrode, separator, and electrolyte. Cells is to be divided into two major
classes primary and secondary. Primary cells are not rechargeable and must be replaced once the reactants
are depleted. Secondary cells are rechargeable and require a DC charging source to restore reactant so
their fully charged state

20
 A battery converts chemical energy into electrical energy by a chemical reaction. Usually the
chemicals are kept inside the battery. It is used in a circuit to power ther components. A battery produces
direct current (DC) electricity (electricity that flows in one direction, and does not switch back and forth).
Using the electricity from an outlet in a building is cheaper and more efficient, but a battery can provide
electricity in areas that do not have electric power distribution. It is also useful for things that move, such
as electric vehicles and mobile phones. Batteries may be primary or secondary. The primary is thrown
away when it can no longer provide electricity. The secondary can be recharged and reused.

LIST OF BATTERY TYPES

* Alkaline battery ( zinc manganese oxide, carbon)

* Aluminum-air battery.

* Atomic battery. Betavoltaics.Optoelectric nuclear battery nuclear micro-battery

* Bunsen cell.

* Chromic acid cell ( Poggendorff cell )

* Clark cell.

* Daniel cell.

* Dry cell.

21
3.8FRAME

The fixed frame forms the base of the 4 wheel forklift by pedal operated vehicle. This frame is made
of Mild Steel (MS). It has four wheels attached to its two sides by sprocket bolt and iron pipe.

A vehicle frame, also known as its chassis, is the main supporting structure of a motor vehicle, to
which all other components are attached, comparable to the skeleton of an organism. Until the 1930s
virtually every car had a structural frame, separate from its body. This construction design is known
as body-on-frame.

3.9 SHAFT

A shaft is a rotating machine element, usually circular in cross section, which is used to transmit
power from one part to another, or from a machine which produces power to a machine which
absorbs power. The various members such as pulleys and gears are mounted on it

22
3.10 Bolts And Nuts

A bolt contains two parts a shank and a head. The cylindrical portion of the bolt is known as the shank. The
shank is threaded at the tail end for a sufficient length so as to effectively engage with a nut. The shape of the
head is depended upon the purpose for which bolt is required. The nut is a type of a fastener which has a
threaded hole in it. The nut is always used in joining with a mating bolt to fasten various parts together.

TYPES OF NUTS AND BOLTS

Different forms and types of nuts and bolts are as follows :

*Form of Bolts

1. Hexagonal-headed bolt

2. Square-headed bolt

3. Cylindrical or cheese-headed bolt

4. Cup-headed or round-headed bolt

5. T-headed bolt

6. Countersunk-headed bolt

*Forms of Nut

1. Hexagonal Nut

2. Square Nut

3. Ring Nut

4. Cap Nut

5. Cylindrical or Capstan Nut

6. Dome Nut

7. Wingnut or Thumb Nut

23
 Washer

A washer is a thin plate (typically disk-shaped, but sometimes square) with a hole (typically in
the middle) that is normally used to distribute the load of a threaded fastener, such as a bolt or nut.
Other uses are as a spacer, spring (Belleville washer, wave washer), wear pad, preload indicating
device, locking device, and to reduce vibration (rubber washer). Washers often have an outer
diameter (OD) about twice their inner diameter (ID), but this can vary quite widely.

Washers are usually metal or plastic. High-quality bolted joints require hardened steel washers to
prevent the loss of pre-load due to Brinelling after the torque is applied.

Rubber or fiber gaskets used in taps (or faucets, or valves) to seal against water leaks are sometimes
referred to colloquially as washers; but, while they may look similar, washers and gaskets are usually
designed for different functions and made differently.

Washers are also important for preventing galvanic corrosion, particularly by insulating steel
screws from aluminium surfaces.

The origin of the word is unknown; the first recorded use of the word was in 1346, however, the
first time its definition was recorded was in 1611.[1]

Washers may also be used in rotating applications, as a bearing. A thrust washer is used when a
rolling element bearing is not needed either from a cost-performance perspective or due to space
restraints. Coatings can be used in attempt to reduce wear and friction either by hardening their
surface, or providing a solid lubricant (i.e. a self-lubricating surface).

24
11.CHAIN

A bicycle chain is a roller chain that transfers power from the pedals to the drive-wheel of a
bicycle, thus propelling it. Most bicycle chains are made from plain carbon or alloy steel, but some are
nickel-plated to prevent rust, or simply for aesthetics.

The chain is a unit of length equal to 66 feet (22 yards). It is subdivided into 100 links[1][2] or 4
rods. There are 10 chains in a furlong, and 80 chains in one statute mile.[2] In metric terms, it is
20.1168 m long.[2] By extension, chainage (running distance) is the distance along a curved or
straight survey line from a fixed commencing point, as given by an odometer.

The chain has been used for several centuries in England and in some other countries influenced
by English practice. In the United Kingdom, there were 80 chains to the mile, but until the early
nineteenth century the Scottish and Irish customary miles were longer than the statute mile;
consequently a Scots chain was about 74 (imperial) feet,[3] an Irish chain 84 feet. These longer chains
became obsolete following the adoption of the imperial system in 1824.[4] This unit ceased to be
permitted to be "used for trade" in 1985.

Advantages of chain.

The main advantages of chain transmission are the possibility to convey either small or important
powers with high security and in a positive way, with limited obstruction e good output which, if the
chain is chosen correctly and suitably lubricated , can reach 98% .

25
CHAPTER-4

26
 DESIGN AND ESTIMATION

Warehousing is the most popular area where the forklifts have proven there worth. In a warehouse,
materials are constantly being move around. So to decrease the fuel wastage we can use the pedal
operated forklift for small distance and small load to transport them. It’s is hard to imagine such an
operation getting alone without an forklifts.

27
4.1 DESIGN CALCULATION
Design parameters consideration are;

1. Motor calculation

Specifications and calculation

* 300 rpm

* 24 v

* 8 N-m

Power required for motor P = (T × N) /9550

Where,

P = Motor power in kW

T = Torque = Force × Gravity × radius

N = speed of motor in rpm

P = (8*300)/9950

P = 25 w

The motor required 25w of a battery to perform the work.

2 Calculation of position of center of gravity with respect to the rear axle

We know that turning Radius of vehicle (R) = 1500 mm.

Also we know that,

Turning radius of vehicle: R = a22 + R12

Where,

a2 = Distance of CG from rear axis.

R1= Distance between instantaneous center and the axis of the vehicle.

To find a2

Load on front axel: Wf=W× a2/ L

Where, Wf = Load on front axle = 17kg (On basis weight distribution)

Total weight of vehicle (W) = 30kg

Wheel base (L) = 2669 mm

28
Therefore,

a2 = 1200 mm

Substituting the value of a2 in the above equation

R1 = 2010 mm

If load apply on the vehicle is 25kg and length 600 mm, width of vehicle 800 mm. Find the reaction force
developed by each wheel and also find torque of each wheel? Here Given Data

W=25kg

Length=600 mm

Width=800 mm

To find reaction force on each wheel (F), torque (T)

r= ( ( a/2)2 + (b/2)2)0.5

r= ( ( 600/2)2+(800/2)2)0.5

r=500 mm

Now

W= 25kg = 25 × 9.81 = 245.25N

Now

Force on each wheel =W/4 = 61.32N

According to newton’s 3rd law of motion

Reaction Force developed by each wheel: F =W/4

= 61.32N

Now

Torque on each wheel: T=W/4 × r

= 30660 N-mm

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4.2 ESTIMATON

Components Quantity Price

1 2000
1.DC MOTOR

2.SPROCKETS 6 500

3.CHAINS 5 500

4.PEDESTAL bearings 8 500

5.SHAFT MS ROUND ROAD OF 600

25MM DIA AND 20MM
DIA OF 8FT

6.FRAME L-ANGULAR LENGTH 1000

OF 20FT

7.TYRES 4 1600

8.FORK 1 500

9.BATTERY 2 1000

Others - 1000

Total Rs 9200/-

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 4.3 Working Principle

Forklift trucks are vehicles designed to move and stack heavy or bulky goods. They are mainlyused in warehouses,
stockyards and other storage areas. Forklift trucks are highly mobile with a verysmall turning circle which allows
them to move easily in confined spaces. On the front of the truck aretwo forks operated by hydraulics. The driver
must fit these forks into the pallets on which goods arestored. The operator then uses the hydraulic forks to lift the
pallet, takes it to where it is needed andsets it down.

Some goods, such as bricks, can be moved by fork-lift trucks without the need for pallets. Theyare stacked in bales
with spaces for the forks. The operator must work carefully as these goods arenot protected by pallets. Some trucks
are fitted with small computer display panels that direct theoperator where to place goods in the warehouse.

Operators may also have to keep records and follow instructions written on a worksheet. Theyare also responsible
for the basic maintenance of the truck. This includes greasing or oiling parts andchanging or recharging the battery.
Forklift truck operators may have to work in a noisy and dustyenvironment. Working outdoors in all weather
conditions may also be necessary.Industrial lift trucks are used for handling materials, parts, products, tools,
equipment, suppliesand 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, tires and load capacities. Themajor factors
that lead to injuries involving the use of forklifts include unsafe driving and materialhandling practices.Although
the term 'forklift', 'fork lift', or 'fork truck' is instantly recognizable, their full, official title isa Fork Lift Truck, due
to the fork shaped tool at the front that traditionally was used to lift pallets. Butnow, like any other piece of
equipment, the forklift has evolved and is available in a wide variety ofstyles, 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 theconcern
manufacturer and consists of both formal instruction and practical training. Training is bothvehicle- and workplace-
specific. The training is a one-time requirement unless the operator isinvolved 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 checklistmust be completed and any defects should be reported and corrected immediately. A truck may
notbe placed into service if any defects are found during the inspection.

This forklift is operated by a chain drive by using pedaling we can move the vehicle forward and revers and it
doesn’t contain steering system. We use the pedal operation for movement and for lifting dc motor has used. To
recuce the use of natural resource usage this pedal operated forklift.

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 CHAPTER-5

32

ADVANTAGES,DISADVANTAGES & APPLICATIONS

5.1 ADVANTAGES
 1.Suitable for indoor use

2.Longer life.

3.Minimum noise level.

4.Eco-friendly operation
5.It can be used in hazardous areas.
6.Huge advantage of forklift is that they have no fuel cost.
7.The best electric forklift is that they have zero emission which causes safe and
8.Healthy environment, That is why they can be called the Green Forklift.
9.The operation cost is low.
10.The life of electric forklift is greater than other types.
11.Maintain better control of material management
12.Reduce product damages
13.Reduce manpower
14.Increase productivity
15.Suitable to transfer frames.

5.2 Disadvantages

1. Operated Its totally manually.

2. Without human effort its not operated.
3. Not fit for heavy weights.
4. More torque is required for operating all the operations.
5. It is heavy weight.
6. Children’s can’t use.
7. Structure is complex

5.3 Applications

1) There is hardly any industry where material handling is not require. The Hydraulics and other type of forklifts
are the most economical solution for all the industries and warehouses where material handling as well as
transportation of it at short distances is required.

2) Fork lifts are used for lifting and transporting all kind of materials like packaged products, raw material and
other equipment.

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3) Warehousing is the most popular area where forklifts have proven their worth. In a warehouse, materials are
constantly being move around. Most of the activity is focused around the loading and unloading of trucks. The
warehousing operation can sometimes take on the appearance of a hive as forklifts of every size and description
scurry about, ferrying boxes and crates from one place to another. A forklift’s design also makes them excellent
machines for stacking and unstacking boxes and crates. Forklifts extreme maneuverability means that they also fit
into small spaces to retrieve cargo. It is hard to imagine such an operation getting alone without forklifts

4) Another popular place where forklifts are used is transportation industry. It may be ship ports, railways or anair
line transportation. Everywhere forklifts are used. The principle and application are same MATERIAL HANDLING,
the only thing differs is the the size and power source of the forklift according to the application for which it is
used.

5) Forklifts are also proven very useful for ship crushing, metal scraps etc. Industry where heavy materials are
required to be lifted and transported.

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CHAPTER-6

35
 6. CONCLUSION:

The mechanical field is improving day by day. Lots of innovative ideas are entering in to the field.
This project is indeed to endow with a comprehensive study of the technical and theoretical aspects of
“FORKLIFT” all the topics covered in this report are essential for the complete understanding and
survey of the title “ 4 WHEEL FORKLIFT BY PEDAL OPERATED”.In the project we have studied
and modified the product called Forklift machine.The reports engrosses different chapter and each is
design in the organized style.

Covering basic introduction, specification, application, and its uses in various industries.

36
CHAPTER-7

37
 REFERENCES

1. https://en.m.wikipedia.org/wiki/forklift
2. https://www.sciencedirect.com/topics/ forklift by pedal operated
3. https://www.slideshare.net/mobile/umeshmeher/forklift
4. https://en.m.wikipedia.org/wiki/pedal operated forklift
5. International Journal of Engineering and Techniques - Volume 3 Issue 2, March-April 2017
6. International Journal of Scientific and Research Publications, Volume 2, Issue 4, April 2012 1
ISSN 2250-3153
7. International Journal of Mechanical Engineering and Technology (IJMET)
Volume 8, Issue 6, June 2017

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