closure report,mobile car jack
DESCRIPTION
final year project reportTRANSCRIPT
INDIAN INSTITUTE OF
TECHNOLOGY,DELHI
MEP202 2ND SEMESTER 2007-2008
COURSE COORDINATOR :PROFESSOR S.R.KALE
MOBILE CAR JACK
TEAM 1-B
CLOSURE REPORT 21.04.2008
1. EXECUTIVE SUMMARY
Our project manufacturing of a Mobile Car Jack is a solution to the perennial
problem occupants of a vehicle getting stranded if the tyre gets flat. We had a
motive in mind, to eradicate this problem. The idea and concept behind the design
was an outcome of spurred innovation of all us in which each one of us contributed
to the fullest. Save some preliminary glitches and dilemma we were able to fine tone
the design to its optimum. The manufacturing was a challenge due to the constraint
on the variety of materials we had at our disposal but our determination; urge as
well the guidance of our instructors helped us transcend all these barriers to come
out with flying colours. Apart from a few inconsequential changes in the design we
were able to manufacture the product well in time. In a nutshell, this project was
very knowledge imparting and gave us a flavour of practical work, the associated
glitches and the pain it takes to do the hands on work.
2. PICS
4. DRAWINGS
PART
NUMBER
NAME MATERIAL QUANTITY REMARKS COST
1 RECTANGULAR SHEET SAE4130,
STAINLESS STEEL
AREA =
450mmx1200mm
THICKNESS = 2mm Taken from project lab
2 PILLOW BLOCK
BEARING
STANDARD 4 YAT 205-100 SKF Rs. 200
10 cm
3 SHAFT(hollow) SAE4130 LENGTH = 1500mm THICKNESS = 3mm From Central
Workshop
[seamless pipe] OUTER DIAMETER= 25mm
4,5 SPHERICAL CASTER DUCTILE STEEL
SWIVEL CASTER
6 4 INCH WHEEL DIAMETER,
LOAD CAPACITY ON TOP
PLATE MORE THAN 125 Kg
Rs. 1800
BLOCK1, BLOCK2 +
BOLT+ BUSH
ASSEMBLY
MILD STEEL 1 100mmx30mmx30mm Rs. 2000
6
7 SQUARE PIPE SAE4130 LENGTH = 900mm 40mmx40mm, Rs. 650
MILD STEEL Thickness = 2mm
8 SQUARE PIPE SAE4130 LENGTH = 1500mm 48mmX48mm, Rs. 1040
MILD STEEL Thickness = 3mm
9 RECTANGULAR PIPE SAE4130 LENGTH = 1200mm 50mmX25mm From Project lab
Thickness = 3mm
10 LOCK NUT, M8 STANDARD 20 From Project Lab From Project Lab
11 BOLT, M8 HARDENED CI 20 WE WILL GET DIRECTLY FROM
MARKET
From Project Lab
12 ROD (FOR HANDLE) MILD STEEL LENGTH = 1200mm 8mm DIAMETER From Project Lab
5. BOM
6. PRODUCT SPECIFICATION
MOBILE CAR JACK
DIMENSION: 400*160*750 mm
WEIGHT: 10KG
RANGE: R9 – R12 WIDE
MAX WEIGHT OF CAR: 1000KG
MAX SPEED: 10Km/hr
MANUALLY OPERATED
7. Performance Acceptance Testing-
i) Testing of applied torque by person to lift the car (It should be easily lifted by a person).
ii) Inflated tyre lifts testing (Firstly, the jack is to be tested on an inflated tyre).
iii) Flat tyre lifts testing (Secondly, it is tested on a flat tyre to check its working).
iv) Testing for tyres (lifting and compatibility) for different cars (This testing is to be performed for at least 3 different types of car tyres).
8. PAT Results-
i) Torque required to lift the car- Car was easily lift able, person can rotate the lever even with one hand with very less effort.
ii) Inflated tyre was lifted easily up to the level of other three tyres on the road. iii) Flat tyre was also lifted. iv) The product was tested on three cars (SANTRO, MARUTI 800 and INDICA). These
were lifted easily. These vehicles were moved upto 200 meters approximately with jack.
9. Failures (other than mentioned in design report)
i) Noise -
There was a noise in the casters when the vehicle was moved.
ii) Vibrations-
Casters and the shafts were vibrating a little due to rough road.
iii) Handle Breakage-
The handle of the rod got broke ( 2 of them) during testing due to torsional stress.
10. SUGGESTIONS FOR IMPROVEMENT
There are numerous chances of improvement in our displayed product which will make the
product safer, reliable, easy to operate, attractive, lightweight and compact as well. Some of
the suggestions are listed below:
1. Use alloys instead of mild steel and cast iron.
2. Casters used to support heavy machines in the CNC lab. Can be used.
3. The two shafts (that are mounted on the bearings) can be covered with a rubber tube of
appropriate thickness which will result in force distribution over an area rather than along a
line and hence less risk of tyre getting damaged.
4. To reduce the force required to install the jack, hydraulic or any other system can be
used.
5. The product can also be made to work as and ordinary jack with the help of some
attachments.
6. Using a ratchet pinion mechanism (instead of nut-bolt) the product can be installed with
the help of foot instead of hand and hence will be of more use to women and old people.
7. Use bigger casters so that the speed of the car can be increased when it is moving on the
jack.
11. SAFETY AUDIT
1. The handle to install the jack is reasonably long so that in case the jack fails the user is far
from getting injured.
2.The welding of the parts are done using electric arc welding and in some cases by gas
welding to impart proper strength reducing chances of failure during operation and hence
any subsequent damage.
3. Since the jack is not attached to any part of the vehicle other than tyres it does not results
in any damage to the body of the vehicle (even in case of failure).
4. Wherever possible edges are smooth and polished to prevent any cuts and injuries.
12. AESTHETICS
ABHAY SHUKLA) The product can be made more attractive by using suitable synthetic
coatings or paints.
SUDHANSHU NAHATA) The product was looking good. It can be improved by making metal
surface smoother by grinding process at certain places, use of metallic colors for painting.
Use of plastic caps at the ends to cover pipes.
TEJESHWI) The weld joints were not as per aesthetics convention, allow room for
improvement, other than that rest was good enough.
PANKAJ KUMAR SHARMA) considering that it was our first endeavour, the aesthetics aspect
was reasonably good save some weld joints which could have been bettered.
GAURAV SHUKLA) The colour combination was quite decent and the product looked really
good which earned us some very beautiful compliments from some of the visitors.
13. COMMENTS FROM THE OPEN HOUSE VISITORS
Great idea, I have suggested to make it women friendly too as women face such a lot
of problem. ( Aparajita Mahapatra)
Good innovative idea, nice thinking. (Kanav)
I would like to buy one. (Gaurav)
Good idea, I would like to see the product in working. (M Raghu)
Very innovative and out of the box thinking. Really of practical use... ( S Dayal)
It is a very good idea and useful in case of emergency on the road. (Dr. Raghu
Echempati)
These are some of the comments out of around 80. Others are attached with the report.
14. COSTING
MONEY:
The total cost for the product comes out to be Rs 5, 00,000/-
This cost includes Labour charges, Machining charges, Material charge, and Transportation
charges. Few of the costing is written with the BOM provided in item no. 5.
Labour Charges: Rs 250/- per hour of work.
Total manual Hours Spend person: 20*14
Therefore labour cost is: Rs 3, 50,000/-
Cost of Lab technicians: Rs. 5, 000/-
Cost of Machinery setup: Rs 1, 00,000/-
Cost of Electricity: Rs 2, 000/-
Cost of consumable Item: Rs 1, 000/-
Cost of material: Rs 5,000/-
15. ASSESSMENT OF TEAM WORK
(Sudhanshu Nahata 2006ME20582)
We had a very good time working in the team and all of the team members have more or
less equally contributed to achieve the task. In the end, I am very happy with the team
effort.
(Abhay Shukla 2006ME20556)
It was a great experience working in the team. Brainstorming, arguing and appreciating
ideas. The work was very well coordinated and work was divided decisively.
(Gaurav Shukla 2006ME10485)
My team members were very cooperative and light mood. All of us almost equally did the
work and also took care of others’ problems in between. All the way, it was great fun and
learning process working as a team member with these guys.
(Tejeshwi 2006ME10525)
We really worked as a team ought to work. It was a pleasure to work with such devoted
people. It gave me an opportunity to strengthen my friendship with peers and also gave me
a wonderful insight into the practical implications of the theory.
(Pankaj Kumar Sharma 2006ME10497)
I liked the experience which was both knowledge imparting and exciting. I learned many
lessons about team work, team spirit, selflessness and hands on work. I would love to do a
similar project.
17. and 18. POSTER and HANDOUT
Team Members
Abhay Shukla, Gaurav Shukla, Pankaj Sharma, Sudhanshu Nahata, Tejeshwi
Faculty Coordinator
Prof. S. R. Kale & Prof. Raghu Echempati
Mechanical Engineering Department
MOBILE CAR JACK
MEP202Design, Innovation & Manufacturing
Innovation
The product is based on a novel objective of enabling car movement and
mobility even with flat tyres.
PORTABLE AND REASONABLY PRICED
CAN BE INSTALLED IN THE SAME TIME AS A NORMAL CAR JACK
GOOD RELIABILITY
AND CAN SUSTAIN THE
INCURRED FORCE
SUITABLE FOR TYRE SIZE
FROM 9” TO 12’’
RECTANGULAR PIPES
PREVENTS
ACCIDENTAL
DERAILMENT OF TYRE
WORKING
• THE APPLIANCE IS
SLIDED ACROSS THE FLAT
TYRE.
• BOLT IS CRANKED WITH
THE HELP OF A METAL
HANDLE.
• AS THE BOLT MOVES
FORWARD,IT CLUTCHES
THE FLAT TYRE BETWEEN
THE TWO RODS MOUNTED
ON THE BODY WHICH
SUBSEQUENTLY LIFTS THE
TYRE.
•THE CAR IS READY TO
MOVE WITH A RELATIVELY
LOWER VELOCITY ON THE
FOUR CASTERS PROVIDED
BENEATH THE FRAME.
THIS PRODUCT IS MAINLY USEFUL FOR:
>DRIVERS
>USERS OF NON TUBELESS TYRES
19. ACKNOWLEDGEMENT
We are very thankful to the people who contributed and helped in the manufacturing of the
project. Among them the most significant are:
To Professor S.R.Kale and Professor Raghu Echempati who guided us throughout the
course.
Ayodhya Prasad Sir (Department Project Laboratory) - He hepled us a lot, trained us to use
all the machinery and tool present in the lab. He even did welding for us which we found
difficult for us.
Sheet Metal Shop In charge (Central Workshop) - He helped us in cutting of sheet.
Forging Shop In charge (Central Workshop) - He guided us in manufacturing of handle.
LEADERSHIP
I had a good leadership experience as this was the first time that I was appointed as a
leader. I experienced both the sides of leadership. On one hand I felt good to be more
responsible, equipped with virtual powers etc. and on the other hand I stood helpless
when one or more team members didn't listen to me or started giving excuses for
delayed work that was being assigned to them. During this period money was also one
of the disturbing factor as team members always insisted that team leader should
finance. This whole process requires a lot of patience from your side. Summing it up
for the juniors, I would like to say that everyone should put themselves in this role at
least once to get the valuable experience. This whole process requires a lot of patience
from your side.