report fyp final jack
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UNIVERSITI KUALA LUMPUR
MALAYSIAN SPANISH INSTITUTE
(TWO LIFTING ARMS CAR
JACK)
BY:
MUHAMAD AFIZ BIN MOHAMMAD
(54136209191)
AIN NATASHA BINTI ZULKUFLI
(54136209015)
JACOB PEREIRA
(54136209195)
Report Submitted to Fulfill the Partial Requirements for the Diploma of
Engineering Technology in Mechanical Design and Development.
JULY 2011
DECLARATION
We hereby declare that this submission is our own work and that to the best
of our knowledge and belief it contains neither material nor facts previously
published or written by another person. Further it does not contain material
or facts which to a substantial extent has been accepted for the award of any
diploma of a university or any other institution of tertiary education except
where an acknowledgement.
……………………………….
(Muhamad Afiz bin Mohammad)
541362090
……………………………….
(Ain Natasha binti Zulkufli)
54136209015
……………………………….
(Jacob Pereira)
54136209195
Date: / /2011
Date: / /2011
Date: / /2011
2
APPROVAL
We have examined this report and verify that it meets the programmed and
University requirements for the Diploma of Engineering Technology in
Mechanical Design and Development.
……………………………….
(Mr. Zainal Nazri bin Mohd Yusuf)
Supervisor
……………………………….
(Mr. Abdul Rashid bin Abdul Rahman)
Date: / /2011
Date: / /2011
3
ACKNOWLEDGEMENT
Two lifitng arms car jack has been developed successfully with a great
contribution of many people within a period of six months. We would like to
appreciate their guidance, encouragement and willingness since without
their support the project would not have been a success.
Firstly we would like to thank God who has been the highest helper for our
project in many ways. Without God we cannot be completing this project
successfully with the weather, time an etc.
We would like to give our sincere gratitude to Mr. Zainal Nazri bin Mohd
Yusuf, who was supervise our project and helping us in many ways, sharing
some information and knowledge, giving us some idea and also help us in
solving problems to make sure our project succeed. We are also grateful to
Mr. Abdul Rasid bin Abdul Rahman who has been behind us guiding all the
projects from and giving us very valuable feedback Both our supervisor who
was a really helpful people who guided us in fabricating so many parts for
our project.
We are also grateful to the whole technician of the Workshop Section
including- Mr. Mohd Faizal bin Osman, Mr. Azren bin Ahmad, Mr. Asrulwadi
bin Ismail, Mr. Mohd Shukor bin Salleh and others for their inspiring
technician, give feedbacks and helping us on how to using workshop
equipments.
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We would also thank our parents and family member for giving us the
financial support and the courage to complete this final year project. We
would like to thank them because of the great advises and support that they
gave us from the starting till the end of this project.
CONTENTS
DECLARATION 2APPROVAL 3ACKNOWLEDGEMENT 4CONTENTS 5LIST OF TABLES 7LIST OF FIGURES 8CHAPTER 1 INTRODUCTION 9
1.1 Introduction 101.2 Project Motivation 161.3 Background 191.4 Problem Statement 211.5 Objectives 241.6 Scope and Limitation 25
CHAPTER 2 LITERATURE REVIEW 262.1 Introduction 272.2 Terminology 32
2.2.1 Design 322.2.2 Jack 32
CHAPTER 3 DESIGN DEVELOPMENT 363.1 Project Development Stages 373.2 Project Fabrication Stages 39
3.2.1 Project Planning and Scheduling 403.2.2 Gantt Chart 43
3.3 Concept of Car Jack 443.3.1 How does a two lifitng arms car jack work? 44
3.4 Fabrication and Development 553.4.1 Confirm Design 553.4.2 Build Mock-Up 55
CHAPTER 4 METHODOLOGY 564.1 Parts Development 57
4.1.1 Outer Body 574.1.2 Gears and Couplings Mechanism 624.1.3 Lifting Arm 674.1.4 Lifting Base 704.1.5 Rollers Part 80
5
4.1.6 Finishing Process 81
CHAPTER 5 RESULT AND DISCUSSION 825.1 Testing the Product 835.2 Problems Facing and Solutions 845.3 Result 85CHAPTER 6 CONCLUSION AND DISCUSSION 876.1 Recommendation 886.2 Conclusion 89REFERENCES 90APPENCISES 91
6
LIST OF TABLES
Table 1 Pahl and Beitz Model of Design ProcessTable 2 Stages of project developmentTable 3 Stages of project fabrication 1Table 4 Structure of product developmentTable 5 Gantt chartTable 6 CNC Milling ProgrammingTable 7 EDM Programming
7
LIST OF FIGURE
Figure 1 Screw lifting jack 10Figure 2 Long floor jack 12Figure 3 Pneumatic jack 12Figure 4 Pneumatic jack 13Figure 5 House jack 13Figure 6 Strand jack 14Figure 7 Current jack in market 14Figure 8 Tire change fail 15Figure 9 Mechanic servicing car 16Figure 10 Electric car jack 20Figure 11 Preparing tools 25Figure 12 Proper located of car jack 26Figure 13 Proper position point of car jack 26Figure 14 Place jack stands 27Figure 15 Lower the car jack to the stand 27Figure 16 Stop lowering the jack 28Figure 17 Spur gear and rack gear 41Figure 18 Marking plate 42Figure 19 Hand sawing machine 42Figure 20 DANOBAT band sawing machine 43Figure 21 Cutting plate process 43Figure 22 Position of hole in plate 44Figure 23 Surface grinding control 45Figure 24 Facing process 47Figure 25 Spur gear 50Figure 26 Position of spur gear and rack gear 50Figure 27 Gear fix into the lifting arm 51Figure 28 Assembling process of arm 51Figure 29 Dimension of lifting arm 52Figure 30 Drilling hole on arm plate 53Figure 31 Grinding process 53Figure 32 Cover of arm set 54Figure 33 Lifting base 1 & 2 55Figure 34 Process of shaping lifting base plate 57Figure 35 CNC Milling 57Figure 36 Lifting base 1 57Figure 37 Bending process 57Figure 38 Lifting base 2 60Figure 39 Cutting process of lifting base using EDM 62Figure 40 Bending process 63
8
Figure 41 Front roller 64Figure 42 Back roller 64Figure 43 Assembled of part project 65Figure 44 Result of project 68Figure 45 Result of project 69
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Chapter 1: INTRODUCTION
1.1 INTRODUCTION
This report describes about the types of jacks that are in the market now
days. It is a device used in workshop’s to lift heavy loads or apply great
forces to carry a vehicle. There are many types or jacks in the market.
Firstly, the mechanical jack. A mechanical jack is a device which lifts heavy
equipment. The most common form is a car jack, floor jack or garage
jack which lifts vehicles so that maintenance can be performed. Car jacks
usually use mechanical advantage to allow a human to lift a vehicle by
manual force alone. More powerful jacks use hydraulic power to provide
more lift over greater distances. Mechanical jacks are usually rated for a
maximum lifting capacity (for example, 1.5 tons, 2 tons, and 3 tons). The
jack shown below is made for a modern vehicle and the notch fits into a
point on the body. Earlier versions have a platform to lift on the vehicles'
frame or axle. This is a common car jack found in car when the car is
purchased by someone from the car dealer’s.
Figure 1 Screw Lifting Jack
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Secondly, the hydraulic jacks are typically used for shop work, rather than as
an emergency jack to be carried with the vehicle. Use of jacks not designed
for a specific vehicle requires more than the usual care in selecting ground
conditions, the jacking point on the vehicle, and to ensure stability when the
jack is extended. Hydraulic jacks are often used to lift elevators in low and
medium rise buildings.
A hydraulic jack uses a fluid, which is incompressible, that is forced into a
cylinder by a pump plunger. Oil is used since it is self lubricating and stable.
When the plunger pulls back, it draws oil out of the reservoir through a
suction check valve into the pump chamber. When the plunger moves
forward, it pushes the oil through a discharge check valve into the cylinder.
The suction valve ball is within the chamber and opens with each draw of the
plunger. The discharge valve ball is outside the chamber and opens when
the oil is pushed into the cylinder. At this point the suction ball within the
chamber is forced shut and oil pressure builds in the cylinder.
In a bottle jack the piston is vertical and directly supports a bearing pad that
contacts the object being lifted. With a single action piston the lift is
somewhat less than twice the collapsed height of the jack, making it suitable
only for vehicles with a relatively high clearance. For lifting structures such
as houses the hydraulic interconnection of multiple vertical jacks through
valves enables the even distribution of forces while enabling close control of
the lift.
In a floor jack a horizontal piston pushes on the short end of a bell crank,
with the long arm providing the vertical motion to a lifting pad, kept
horizontal with a horizontal linkage. Floor jacks usually include castors and
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wheels, allowing compensation for the arc taken by the lifting pad. This
mechanism provides a low profile when collapsed, for easy movement
underneath the vehicle, while allowing considerable extension.
Figure 2 Long Floor Jack
Figure 3 Pneumatic Jack
The third type of jack is the pneumatic jack. It is a hydraulic jack that is
actuated by compressed air - for example, air from a compressor -
instead of human work. This eliminates the need for the user to actuate
the hydraulic mechanism, saving effort and potentially increasing speed.
Sometimes, such jacks are also able to be operated by the normal
hydraulic actuation method, thereby retaining functionality, even if a
source of compressed air is not available.
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Figure 4 Pneumatic Jack
Next, a house jack, also called a screw jack is a mechanical device primarily used to lift
houses from their foundation. A series of jacks are used and then wood cribbing
temporarily supports the structure. This process is repeated until the desired height is
reached. The house jack can be used for jacking carrying beams that have settled or for
installing new structural beams. On the top of the jack is a cast iron circular pad that the
4" × 4" post is resting on. This pad moves independently of the house jack so that it
does not turn as the acme-threaded rod is turned up with a metal rod. This piece tilts
very slightly but not enough to render the post dangerously out of plumb.
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Figure 5 House Jack
Lastly, is the strand jack. It is a specialized hydraulic jack that grips steel
cables; often used in concert, strand jacks can lift hundreds of tons and are
used in engineering and construction.
Figure 6 Strand Jack
Figure 7 Current Jack in market
Well, this is the types of jacks that are in the market at this moment. In
conclusion, we can say that jack’s are meant for carrying heavy loads.
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1.2 PROJECT MOTIVATION
An automotive jack is a device used to lift of a vehicle into the air in order to
facilitate repairs. Most people are familiar with the basic car jack (manually
operated) that is still included as standard equipment with most new cars.
These days, a car jack is an important tool especially in automotive industry
and workshop to helping technician and mechanic repairing their customer’s
vehicle with more safety precaution and quickly.
Working near a vehicle that is supported by a car jack can be fatal. In
Australia, over the last four years at least 19 people have been crushed and
killed by a vehicle while they were working. All the deaths were men and
involved the vehicle being lifted or supported in the wrong way. Home
mechanics are most at risk of this type of death or injury.
15
Figure 8 Tire change fail
In some cases the worker was killed when the vehicle was not secured by
chocks and the vehicle rolled on top of them, or the structures used to
support the vehicle failed. On average, 160 injuries are associated with car
jacks each year. Injuries have ranged from amputation to fractures and crush
injuries. The correct use of jacks can prevent death or injury.
Figure 9 Machanic servicing car
Furthermore, an organization called the American Lift Institute (ALI) was
established to promote improvements in automotive lift technology,
especially in the area of safety. As recently as the late 1990s, car lift or jack
manufacturers were allowed to declare that their products were safe even
though they did not meet any set standard.
Thanks to ALI's cooperative venture with the American National Standards
Institute, all jacks and lifts must meet a set number of performance
standards in order to be ALI/ANSI certified. Improvement in automotive car
jack is really needed to make the tool more efficient, user-friendly, practical
to use, changes in industry direction and most importantly high safety
features. Further research on car jack is very important.
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1.3 BACKGROUND
In the repair and maintenance of automobiles (car), it is often necessary to
raise an automobile to change a tire or access the underside of the
automobile. Accordingly, a variety of car jacks have been developed for
lifting an automobile from a ground surface. Available car jacks, however,
are typically manually operated and therefore require substantial laborious
physical effort on the part of the user.
Furthermore, available jacks are typically large, heavy and also difficult to
store, carry or move into the proper position under an automobile. In
addition, to the difficulties in assembling and setting up jacks, such jacks are
generally not adapted to be readily disassembled and stored after
automobile repairs have been completed.
In light of such inherent disadvantages, some researcher including students
tries to generate a new idea and their attitude on how to develop an Two
lifitng arms car jack for our future.
However, due to their size and high costs of purchasing and maintaining this
car jack, such Two lifitng arms car jacks are not available to the average car
owner. Engineering is about making things simpler or improving and
effective. So we try to develop a car jack in the small scope as an experiment
so that it could be a signal to the world on our effort to solving these
problems nowadays.
There also reports on car jacks which lead to a serious number of accidents.
These are due of safety features that are on conventional car jacks are not
enough. A specified jack purposed to hold up to 1000 kilograms, but tests
undertaken by Consumer Affairs has revealed that it is fails to work after
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lifting 250 kilograms and may physically break when it has a weight close to
its 1000 kilograms capacity.
Whilst no injuries have been reported to date, it was rising expressed
concerned about the dangers associated with the use of a vehicle jack that
does not carry the weight it is promoted to hold. Tests have proven that the
jack has the propensity to buckle well under the weight it is promoted to
withstand, and it doesn’t meet the labeling or performance requirements of
the Australian Standard for vehicle jacks.
The purpose of this project is to develop a car jack which is easy to be
operated, safe and able lift and lowering the car without involving much
physical effort. It is almost fulfill automotive industry requirement especially
in workshop to help mechanics and technician make their works easily
without any problems.
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1.4 PROBLEM STATEMENT
According to this necessity, we have find out the entire user’s problem
(especially drivers and mechanics) and try to solve it also developed this
product of car jack that existing on the market become more better based on
technology provided nowadays.
Present car jack do not have a lock or extra beam to withstand the massive
load of the car. This is for the safety precaution in case if the screw break.
Besides, present car jack just have only one lifting arm to support the load.
With this new design, we try to minimize the size of car jack with maximum
lifting capacity so it can folded up in the vehicle and safe some space, lighter
the weight of material used and also to ensure the stability when the jack is
extended so anyone can bring it easily.
Furthermore, available jacks are typically large, heavy and also difficult to
store, carry or move into the proper position under an automobile. Suppose
car jacks must be easy to use for whoever person and easy to control the
movements of the car jack.
Lastly, normally all car jacks cannot be change or modified if it is spoil. If it
spoils, the only way is to get a new one. So the cost of buying it is expensive.
The price depends on the load that the jack can be carried.
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From the problems and our effort to develop the car jack to be as Two lifitng
arms car jack, we’ve list the problem solution as shown below:-
i. We’ve developed this car jack with two lifting base that can stand with
any weight of vehicle and increase the stability and capability than one
lifting base as usual. This allow technician and users do their work
safely.
ii. First of all, we’ve planned to use a motor for supply power to the car
jack. But it is not stronger at all especially when there is sudden black
out and we need to make sure the motor is function every time before
it can be use.
Figure 10 Electric car jack
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We use hydraulic system to the jack which used a fluid, which is
incompressible, that is forced into a cylinder by a pump plunger. Oil is
used since it is self lubricating and stable.
iii. This Two lifitng arms car jack is jacking from the side, so the mechanic
has more space at the front side to do their works.
iv. When this product is not been used, it can folded up and the roller
made inside the base can move freely.
v. The lifting base of Two lifitng arms car jack can be extended to the size
of vehicle (width) and it was make by rubber padded lifting platform
prevents scratching and protects the vehicle.
vi. We used mild steel that is cheap, high stiffness and strong. Most of
mild steels are easy to machine and weld.
vii. We also use and fabricate parts that can be dismantled. This is for
maintenance purpose of the jack.
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1.5 OBJECTIVES
In order to fulfill the needs of present car jack, some improvement must be
made base on the problem statement:-
i. To design a car jack that is safe, reliable and able to raise and lower
the height level
ii. To design and fabricate the car jack which has develop with more
multi-functionality car jack.
iii. To design a car jack with easy maintenance and less cost
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1.6 SCOPE AND LIMITATION
i. A simple car jack that used for workshop and automotive industry.
ii. These car jacks are prohibited from using for lorry, bus and any heavy
vehicle.
iii. The developed car jack can only withstand below 2 ton of load.
iv. The developed car jack must be operated on a flat surface.
v. The developed car jack is only a prototype and not readily functioning
as commercial product.
vi. The design is based on current lifting base in the market with some
comparison and adjustment.
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Chapter 2: LITERATURE REVIEW
1.1 INTRODUCTION
The main purpose of this literature review is to get information about the
project from reference books, magazine, journals, technical papers and web
sites. In this chapter, the discussion will be made base on all the resources.
First of all, the concept of our product was found by doing some research on
how the car jack lifting cars (vehicle) by us at Kulim, Kedah and surfing some
videos car jack lifting cars (vehicles) by internet. Below is the manual way of
lifting cars (vehicle) by a car jack.
This how-to article aims to help illustrate proper vehicle jacking procedures.
As a disclaimer, we always recommend that you read your vehicle's manual
(or better yet - the factory workshop manual) before attempting any service
items. In this how to, you will be required to know and identify the factory
approved "jack points". Typically, these points can be found under
"Emergency" in the vehicle operator's manual.
Because of the dangers of having a 1000+ kg vehicle looming over you as
you work, we will accept absolutely no responsibility for any accidents that
may occur while you service your vehicle (*one of the reason for us
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developing the car jack with more safety precaution). Safety is everybody's
responsibility- the following article will attempt to reinforce this concept.
Before you buy jack-stands, and a floor jack be sure that each component is
strong enough to support at least half of the vehicle's "curb weight".
Figure 11 preparing tools
i. As safety is a major focal point of this write up, all steps will have some
proximity to safe practices - the first step is a subtle example. Before
you consider jacking up a vehicle, find as flat work area as possible.
ii. Move the vehicle into position. You should place cinder blocks, 4 x 4
blocks, or similar large wedges in front and behind the wheels which
will remain on the ground during the initial jacking process.
iii. Be sure to chock the front wheels. If the vehicle is front-wheel drive,
put the vehicle into reverse gear. State the floor jack in the approved
25
factory location. Be sure to place the jack in an accessible location,
free of interference with any vehicle chassis parts.
Figure 12 Proper located of car jack
iv. Begin jacking the vehicle up using the floor jack. Be very cautious
whilst raising the vehicle. This is where most accidents occur.
Figure 13 proper position point of jack
26
v. Once the vehicle is raised sufficiently, place the jack-stands under the
factory approved jacking points.
Figure 14 Place jack-stands
vi. Be sure to always use a minimum of two jack-stands when raising the
front or rear of a vehicle.
Figure 15 Lower the car to the jack stands
vii. Then, you may slowly lower the vehicle onto the jack-stands. If you run
into problems, jack the vehicle back up and re-position or re-plan your
jacking sequence.
27
Figure 16 Stop lowering the jack
viii. Stop lowering the jack and raise it back up one "notch. Give the vehicle
a slight nudge to ensure that the forces you will exert during your
mechanical procedures will not cause the vehicle to become unstable
and fall off the jack-stands thus killing someone below. Once you are
satisfied that you have done to make the worksite as safe as possible,
you have completed that jacking up of your vehicle.
1.2 TERMINOLOGY
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In this section, all the terminology on this project is presented.
1.2.1 Jack
A mechanical jack is a device which lifts heavy equipment. The most
common form is a car jack, floor jack or garage jack which lifts vehicles so
that maintenance can be performed. Car jacks usually use mechanical
advantage to allow a human to lift a vehicle. More powerful jacks use
hydraulic power to provide more lift over greater distances. Mechanical jacks
are usually rated for a maximum lifting capacity (for example, 1.5 tons or 3
tons).
1.2.2 Design
To design is either to formulate a plan for the satisfaction of a specified need
or to solve a problem. If the plan results in the creation of something having
a physical reality, then the product must be functional, safe, reliable,
competitive, usable, manufacturable, and marketable.
These terms are defined as follows:
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i. Functional: The product must perform to fill its intended need and
customer expectation.
ii. Safe: The product is not hazardous to the user, bystanders, or
surrounding property. Hazards that cannot be ‘designed out’ are
eliminated by guarding (a protective enclosure); if that is not possible,
appropriate directions or warning are provided.
iii. Reliable: Reliability is the conditional probability, at a given
confidence level, that the product will perform its intended function
satisfactorily or without failure at a given age.
iv. Competitive: The product is a contender in its market.
v. Usable: The product is ‘user friendly’ accommodating to human size,
strength. Posture, reach, force, power and control. The developed car
jack is only a prototype and not readily functioning as commercial
product.
vi. Manufacturing: The product has been reduced to a ‘minimum’
number of parts. Suited to mass production, with dimensions,
distortion, and strength under control.
vii. Marketable: The product can be bought, and service (repair) is
available.
It is important that the designer starts by identifying exactly how to
recognize or get a satisfactory alternative, and how to distinguish between
two satisfactory alternatives in
order to get a perfect solution. From this, optimization strategies can be
formed or selected.
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Then the following tasks unfold:
i. Invent alternative solution.
ii. Establish key performance metrics.
iii. Through analysis and test, simulate and predict the performance of
each alternative, retain satisfactory alternatives, and discard
unsatisfactory ones.
iv. Choose the best satisfactory alternatives discovered as an
approximation to optimality.
v. Implement the design.
The characterization of a design task as a design problem can introduce the
idea that, as a problem, it has solution.
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Chapter 3: DESIGN DEVELOPMENT
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Table 1 Pahl and Beitz Model of Design Process
3.1 PROJECT DEVELOPMENT STAGES
Here, we have list the combination method used in order to accomplish our
project. We go through this procedure around four months to make and
gather some information, drawing process, and concepts of the project.
i. Doing some research to the already existing car jack
ii. Doing survey on some workshop’s about car jack
iii. Research done to improve the weakness of car jack
iv. Using common tool or equipments any mechanical works.
v. Getting information for supervisor’s about the project development.
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Table 2 Stages of project development
3.2 PROJECT FABRICATION STAGES
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3.2.1 Project Planning and Scheduling
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Table 3 Stages of project fabrication 2
This project is concern to mechanical and development process, which we
create a model of a new car jack with some improvement and development.
Furthermore, the project coalesce with mechanical engineering, technical
drawing, and metrology needs. Formerly, before designing the products and
process plan take in action, some study and research is being approach to
advisors and all group members. Moreover, this is to ensure that we could
carry out the task given in the specific time and to achieve the objective of
the project.
Several actions that have been done before fabricate the product are:-
i. Brainstorming
Brainstorming is a process for developing creative solutions to
problems. It works by focusing on a problem, and then deliberately
coming up with as many solutions as possible and by pushing the
ideas as far as possible. One of the reasons it is so effective is that
the barnstormers not only come up with new ideas in a session, but
also spark off from associations with other people’s ideas by
developing and refining them.
ii. Analysis
Since our project is based on automotive industry requirements, we
gathered all the information from supervisor, lecturers, and
technicians and also access the internet. We had some survey with
some technician to know some of their problems with the current
jack that might help us in this project.
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The existing product in the international market is almost not
suitable for the automotive industry because of the lacking safety
and less functionality. Therefore our group has decided to fabricate
the same car jack with some improvement and development that
everyone can use it.
iii. Product development
Our product development is based on 3 stages. These three stages
consists on mechanical section. From the mechanical section stages
including drawing and design,, build the structure and lastly testing
the product.
Table 4 : Structure of product development
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Through this stage, there were confirm designed for the product
which has been agreed by the entire group’s members and also our
supervisor and co-supervisor.
iv. Flow chart
Flow chart is one of the 7 Basic Quality Control Tools. It is a diagram
that visually shows how resources move through various operation
of the production system. It shows the entire stage of the
production where the operation must be carried out following the
sequences. The flow chart makes it easier to visualize the
production operation. If any problems occur during stage, the
process needs to be returned back to their earlier stage.
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3.2.2 Gantt chart
Gantt chart represents graphically on a time scale as to when certain
operation would be performed. It is also useful in recording the progress of
the schedule. The activities are listed vertically and the time period is
indicating horizontally. It is also known as the bar chart.
Table 5
TASK DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Detail drawing / /
Confirm design /
Buy material / /
Check compatibility / /
Part fabrication / / / / / / / / /
Assemble / / /
Project testing / / /
Finding problems / / / / / /
Prototype / /
Final presentation /
Submission report /
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3.3 CONCEPT OF CAR JACK
3.3.1 How does a two lifitng arms car jack work?
i. The Mechanism
A car jack is a mechanical device that allows drivers and mechanics to
get underneath a car, usually to change a tire, oil or some body part
like brakes or struts. When most people hear the term floor jack, they
think of the automobile floor jack. It uses a pump arm, hydraulics to lift
vehicles to gain access to the undercarriage. The jack makes easy work
out of changing a tire or doing a brake job. This is not to be confused
with a hydraulic lift used in auto repair shops. A floor jack needs solid
ground or concrete to give it a good base that doesn't shift. There is a
lip that can be attached to the automobile itself and is gently raised by
pumping the arm and hydraulic system .The jacks are rated by the
amount of weight they can lift safely. A 2 jack is what you would
normally carry around in your car to change a tire or carry the front
part of the car to perform repair in front of the car (the place the engine
is).
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ii. Get the car jack to lift up the car.
The Two lifitng arms car jack uses the same concept as the floor jack
used in workshop. Where by there’s a holder to jack the jack up. By
pressing the holder up and down, the arm will raise up because of the
extension on the piston from the hydraulic system which pushes the
rack gear to left arm of the jack. And the right arm has a gear that goes
on the rack gear, so when the rack gear moves forward the gear on the
arm moves to lift the arm.
Figure 17 Spur gear and rack gear
iii. Bringing the Car Down
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There is a lot of weight supported by the jack. Make sure to follow all
the safety suggestions, and that the jack is placed on a flat, concrete
surface and no one is sitting in the car. The car descends by reversing
the process: turn the screw counterclockwise.
Chapter 4: METHODOLOGY
4.1 PARTS DEVELOPMENT
4.1.1 OUTER BODY
Step 1: Cut and shape the outer body
i. First, we measure and marking the steel plate using scriber based on
the dimension in drawing.
Figure 18 Marking plate
ii. Then, we cut the steel plate using hand sawing machine in the work
shop.
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Figure 19 Hand sawing machine
iii. After that, we use DANOBAT band sawing machines to cut the angle of
30’ at the end of the steel plate.
Figure 20 DANOBAT band sawing machine
iv. Because design of the steel plate is quiet difficult to fabricate using the
machines; we had to go to the old-school method that is by using a
handsaw and files. We request G-Clamp and Hand Saw at the FYP
Cabin’s technician to cut it by our effort.
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v. We use flat file and hand grinding to make
the finishing.
vi. Finally, we’ve finish to cut, measure and shape the outer body for Two
lifitng arms car jack.
Step 2: Drilling hole
i. First, we measure and marking the steel plate using scriber based on
the drawing, dimension and mock-up.
Figure 22 Position of hole on plate
ii. Using nail punch that struck by hammer, we marking the position that
we want to drill. (7 holes; two for shaft roller, two for pivot points of
arm, one for gear shaft, one for roller and the rest for hydraulic jack)
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Figure 21 Cutting plate process
Step 3: Surface Grinding
Figure 23 Surface Grinding Control
i. Using Surface Grinding Machine, we remove the rust and make the
plate thinner than the original width as 6 mm tp 4 mm.
ii. Procedure for Use :-
i. The first step in using the surface grinder is to make sure that
the material we wish to shape can be used in the grinder. Soft
materials such as aluminum or brass will clop up the abrasive
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wheel and stop it from performing effectively, and it will then
have to be cleaned. This process is explained by the technician.
The maximum size of a material that the grinder can machine is
18” long by 8” wide by 6” high.
ii. The next step is to make sure the material is secured. This is
done by use of a vice, and then by engaging the magnetic clamp.
Once the material is secure, it must be manually positioned
under the abrasive wheel. This is done by turning the longitude
and latitude wheels located on the front of the grinder. The
abrasive wheel itself can be moved slightly to get the material in
the perfect position.
iii. Then the machine may be started. It should reach maximum
speed before you try to use it for the safety reasons mentioned
before. If the wheel is working properly, then the hydraulic table
can be activated which will then begin to oscillate under the
wheel, cross-feeding towards or away from you as required. The
automated speed and direction of the table’s oscillations can be
set as required or manually used when very precise work needs
to be done.
iv. If needed, a lubricant may be used to speed up or facilitate the
grinding process. For this machine “Cut well 45” is used. It is
delivered via a tube beside the wheel, and falls onto the material
being used. The excess fluid is then drained into the reservoir.
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4.1.2 GEARS AND COUPLINGS MECHANISM
1 st and 2 nd coupling
The 1st coupling is used to join the piston of the hydraulic and the rack gear.
The part is done by lathe machining. The 2nd coupling is used to join the rack
gear with the shaft that is linked to the arm of the jack.
Figure 24 Facing process
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Procedure
1. Clamp the work piece onto the Chuck of the lathe machine.
2. Check the dimension of the work piece using a vernier caliper to avoid
mistake.
(Diameter of the work piece 34mm)
3. Set the cutting tool, and then drill a hole using the center drill.
4. Push the life center to the work piece. It to avoid the work piece from
coming out of the jaw’s of the Chuck.
5. On the machine, and face the work piece. Then perform turning
process.
6. Turn the work piece till the diameter is 30mm and the length of 50mm.
7. Drill a hole of 10mm on the work piece.
8. Then change the tool to the grooving tool.
9. Perform internal grooving for another 10mm.
10. Off the machine and remove the work piece.
11. Performed this procedure for the second coupling.
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Then Conventional milling is used to make the hole for the coupling so that
the rack gear can be fitted into the coupling. We had to use Conventional
milling because the Lathe machine cannot perform the cutting of a square
shape.
Procedure
1. Mark the center of other side of the work piece.
2. Clamp the work piece (standing position) using the clamps on the
conventional milling machine.
3. Clamp a drill bit of 10mm and drill the center. On the machine.
4. Remove the Arbor for the machine.
5. Clamp the end mill of the diameter 8mm onto the arbor, and clamp it
to the machine.
6. Start making a Square by making using the end mill. The width of
20mm and length of 20mm on the work piece with the depth of 20mm.
7. Performed this to both of the work piece.
8. Stop the machine, and change the Work piece in sleeping positon.
9. Then change the tool, from the end mill to the drill bit to drill a hole.
This hole is for the M4 screw that is used to clamp the gear with the
coupling.
10. Then stop the machine, and remove the work piece.
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11. Take the 1st coupling and lay it on the sleeping position. The part
that is lathe.
12. Take a drill bit of size diameter 20mm and drill the side. This is to
hole the hydraulic piston and the coupling.
13. Off the machine and remove the work piece.
14. Clean the machine.
Gears
The gears in this project, we had to purchase it from a gear shop in Seberang
Perai. This is because we do not have the knowledge and the tools to make a
gear in our university. Two solid spur gears and a rack gear.
Figure 25 Spur gear
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Figure 26 Position of spur ger and rack gear
Figure 27 Gear fix into the lifting arm
Using conventional milling, we make two holes diameter 8.3 mm to insert
two shafts into it so the first gear that attached to the arm will be in fix
condition.
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Figure 28 Assembling process of arm
4.1.3 LIFTING ARM
Step 1: Cut and shape the arms
i. First, we measure and marking the steel plate using scriber based on
the dimension in drawing.
Figure 29 Dimension of lifting arm
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ii. Then, we cut the steel plate using shearing machine that is in work
shop nearby the basic fitting workshop.
Step 2: Drilling hole and surface grinding
i. After that, we just follow the same step of making the outer body with
drilling hole using Conventional Milling and remove rust using Surface
Grinding Machine at the four pieces of our lifting arms.
Figure 30 Drillipng process
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Figure 31 Grinding process
Step 3: Welding the top cover of the lifting arm
i. Welding is a fabrication that joints materials by causing coalescence.
This is often done by melting the work pieces and adding a filler
material to form a pool of molten material (weld pool) that cools to
become a strong joint.
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Figure 32 Cover of arm set
4.1.4 LIFTING BASE
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Figure 33 Lifting base 1 and 2
1 st lifting base
Step 1: Measure and marking the steel plate
i. First, we measure and marking the steel plate using scriber based on
the dimension in drawing.
Step 2: Computer Numerical Control Milling (CNC Milling)
i. Using Computer Numerical Control Milling (CNC Milling), we keep in the
programming to cut the steel plate.
Table 6 : CNC Milling Programming
N010 G54
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N020 T1D1
N030 M06
N040 G00 X0 Y0 Z10
N050 M08
N060 G90 G94 G97 G17 F400 S1000 M03
N070 G41
NO80 G00 X-10 Y-10 Z10
N090 G01 X0 Y99.6
N100 G01 X0 Y114.6
N120 G02 X50 Y114.6 R25
N130 G01 X183.
6
Y114.6
N140 G02 X233.
6
Y114.6 R25
N150 G01 X233.
6
Y99.6
N160 G02 X216.
1
Y73 R45
N170 G03 X166.
1
Y13 R105
N180 G01 X67.5 Y13
N190 G03 X17.5 Y73 R105
N200 G02 X0 Y99.6 R45
N210 M09
N220 M30
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Figure 34 Process of shaping lifting base plate
Figure 35 CNC Milling machine
Step 3: Conventional Milling
i. After that, we make two slots on the work piece which this slot
functioning as a sliding slot to the lifting base 2. We use conventional
lathe to done this task.
Figure 36 Lifting base 1
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Step 4: Drilling porcess
i. Next, we drill four hole with diameter 8.3 mm.
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Figure 37 Lifting base 1
Step 5: Bending process
Figure 38 Bending process
In press brake forming, a work piece is positioned over the die block and the
die block presses the sheet to form a shape. Usually bending has to
overcome both tensile stresses as well as compressive stresses. When
bending is done, the residual stresses cause the material to spring back
towards its original position, so the sheet must be over-bent to achieve the
proper bend angle. The amount of spring back is dependent on the material,
and the type of forming. When sheet metal is bent, it stretches in length.
2 nd lifting base
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Figure 39 Lifting base 2
Step 1: Measure and marking the steel plate
i. First, we measure and marking the steel plate using scriber based on
the dimension in drawing.
Step 2: Electrical Discharge Machine
i. Using Electrical Discharge Machine, we keep in the programming to cut
the steel plate.
Table 7 : EDM Programming
N010 G54
61
N020 T1D1
N030 M06
N040 G90 G94 G97 G17 F400 S1000 M03
N050 G41
N060 G01 X-55 Y-53.8
N070 G01 X-11 Y-53.8
NO80 G01 X-11 Y-73.6
N090 G03 X-42 Y-
104.6
I-31 J0
N100 G01 X-102 Y-
104.6
N110 G03 X-133 Y-73.6 I0 J31
N120 G01 X-133 Y-34
N130 G03 X-102 Y-3 I31 J0
N140 G01 X-42 Y-3
N150 G03 X-11 Y-34 I0 J-31
N160 G01 X-11 Y-53.8
N170 G01 X-5.5 Y-53.8
N180 M30
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Figure 40 Cutting process of EDM
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Step 3: Drilling process
i. After that, we just follow the same step of making the first lifting base
with drilling hole using drill press. (our steel plate size and width are
smaller, so that we can use this machine than CNC or conventional
milling machine)
Step 4: Bending process
Figure 41 Bending process
In press brake forming, a work piece is positioned over the die block and the
die block presses the sheet to form a shape. Usually bending has to
overcome both tensile stresses as well as compressive stresses. When
bending is done, the residual stresses cause the material to spring back
towards its original position, so the sheet must be over-bent to achieve the
proper bend angle. The amount of spring back is dependent on the material,
and the type of forming. When sheet metal is bent, it stretches in length.
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4.1.5 ROLLERS PART
Step 1: Front rollers assembled
i. We attach the shaft and roller into the hole of the body.
Figure 42 Front roller
ii. We put washer and nut at the end of the shaft.
Step 2: Behind rollers assembled
i. First, welding the cover plate of the behind rollers to the body. We
need to make sure that the parts is stable and strong to lift heavy load.
ii. Drill hole on the top of the cover plate so we can put bolt, washer and
nut through it.
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Figure 43 Back roller
4.1.6 FINISHING PROCESS
After all the tasks have done the fabricating process, we assembled all the parts to the as a one product.
Figure 44 Assembled of part
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Chapter 5: RESULT AND DISCUSSION
5.1 TESTING THE PRODUCT
Finally, after the product had finished, we have try to test it whether it is
functional or not. Besides, we have also recorded it into the video to show
the movement of mechanism.
Based on the testing that we make on the product, the mechanism is
completely functioning including:-
i. Movement of rack gear and spur gear
ii. Movement of hydraulic jack and shaft to the end that attached with
coupling parts
iii. Movement of sliding lifting base one and two
iv. Movement of the lifting base when we lift the jack
v. Movement of the roller at the bottom of the car jack
5.2 PROBLEMS FACING AND SOLUTION
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i. At first, the lifting arm is not in stable condition especially when lifting
load so we welding the top cover onto it.
ii. We planned to attach the gear to the arm into the fix condition by
welding, but after a few discussions, we discuss to drill two hole on the
gear.
iii. First design, rack gear at the bottom of the jack is not support by
anything. And we found a problem that the rack gear will bending
when lifting the load. So, we put a shaft at the bottom of the body to
support the rack gear.
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5.3 RESULT
The Fabrication of Two lifitng arms car jack is successfully complete by our
group according to the planned. All of us were really excited in completing all
the tasks to complete this project as well.
All of the figure below shown about our parts and product :-
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Figure 45 Result of project
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Chapter 6: CONCLUSION AND DISCUSSION
6.1 RECOMMENDATION
There are some parts of our product that can be upgrade in the future such
as:
i. The mechanism itself
For example, the gear can be changed in size to the smaller one to
decrease the weight of the two lifting car jack.
ii. The hydraulic system also can be changed by using the power motor
with details safety and precaution to lifting the car jack.
iii. The two pairs of roller at the bottom of car jack body can be changed
to the 360’ movement so the car jack can move freely.
iv. The sliding of lifting car jack
For example, current product using a roller can be changed to the bearing components so the sliding lifting base can be more smoothly.
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6.2 CONCLUSION
Finally, we have managed to complete our final year project and successfully
achieved the objectives. Furthermore, the Two lifitng arms car jack had
accomplished the objectives such as:
i. To design a car jack that is safe, reliable and able to raise and lower
the height level
ii. To design and fabricate the car jack which has develop with more
multi-functionality car jack.
iii. To design a car jack with easy maintenance and less cost
Besides, during developing project, all of us had learned a lot of a new knowledge such as fundamentals of the operation and about the time management that is very important to make sure the project is finished within the time given. Moreover, we also study about the system, design of the parts, material, and safety precautions during the project method.
In addition, hopefully our product will help our automotive industry especially to the users, technicians and workers, in improving the current car jack so we can avoid any accidents that may be occur when using the car jack.
Lastly, suspiciously we can practice and applied all of the knowledge’s and experience that we have learned from the first semester until the last semester and also learned from our final year project.
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REFERENCES
i. R.C. Hibbeler, (2005), Mechanics of Materials, Prentice Hall Pearson Education South Asia Pte Ltd
ii. Ferdinand P. Bee, E. Russell Johnston,Jr, Elliot R. Eisenberg (2004), Vector Mechanics for Engineers,Tata McGraw-Hill
iii. Robert L. Mott (2006), Machine Elements in Mechanical Design, Prentice Hall Pearson Education South Asia Pte Ltd
iv. Alawiah Ariffin (2009), Complete Reference Matriculation Physics 1,Oriental Academic Publication
Internet Resources
http://www.efunda.com/processes/metal_processing/bending.cfm
http://www.botlanta.org/converters/dale-calc/gear.html
http://www.roymech.co.uk/Useful_Tables/Drive/Gears.html
http://en.wikipedia.org/wiki/Jack_(device)
http://en.wikipedia.org/wiki/Lathe
http://www2.northerntool.com/auto-jacks.htm
http://en.wikipedia.org/wiki/Milling_machine
http://www.fixya.com/tags/car_jack
http://www.workshopmachinery.com/
APPENDICES
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