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.