report mobile car jack

MEP 202: Design, innovation and Manufacturing

1B

Mobile Car Jack Documentation Report

Sudhanshu Nahata (Group Leader)

Abhay Shukla

Gaurav Shukla

Pankaj Kumar Sharma

Tejeswi

1.1.1.1. PROJECT DEFINATIONPROJECT DEFINATIONPROJECT DEFINATIONPROJECT DEFINATION Project Proposal

Date January 14th , 2008

Project Title Mobile Car Jack

Project Team Name Role

Project Dates Start: January 14, 2008 Completion: April 12, 2008

Project Objective Statement What will you do, by when, and what resources (people and things) do you need to get it done?

SUDHANSHU NAHATA Project Leader

PANKAJ KUMAR SHARMA Manufacturing Head

ABHAY SHUKLA Logistic

GAURAV SHUKLA Analyst, Finance

TEJESWI Material Selection

By 12th

of April’08, we will complete the manufacturing of our product. After that we

will test mobile car jack for reliability by using it in different cars under different

environments. In the mean time we will arrange for appropriate materials from the

market. Then we will discuss how we can easily manufacture the product using our

knowledge and with the help of workshop technician like in welding, machining etc.

so that we can learn the process used in manufacturing. We need to access workshop

for manufacturing during March-April.

Completion Criteria

What should the end result of the project look like? How will you know you’re done? How will

you judge the quality of the results?

The end result should be a functional mobile car jack which should be

capable of lifting a car wheel and the person should be able to push or drive

the car up to a certain distance. It should be easily usable and should not

break while loading. It should not harm rim and tyre of car during its

operation.

NOTES:

We have decided to do most of our work on weekends as we have two full

days to do work.

2.2.2.2. PROJECTPROJECTPROJECTPROJECT PLANNINGPLANNINGPLANNINGPLANNING PROJECT TASK LIST

Date January 21st

2008 Project Title MOBILE CAR JACK

Number Task Owner’s Initial How this task is completed

1. Concept of Product GS Listing out the things that bug us. Thinking

of innovative things.

2. Design Alternatives SN Make design by using one of the

mechanisms that will do the required work.

3. Design Selection SN Eliminating designs by using Pugh’s , Pahl

and Beitz and Dominic method

4. Dimensioning GS By referencing a suitable car wheel, all

dimensions are to be taken.

5. Solid Works PS Using the taken dimensions, a CAD model is

prepared.

6. Analysis of Design AS Removing flaws in designing by using POKA

YOKE and TRIZ analysis

7. Design Improvement TS Incorporating various concepts in design

which came by above analysis

8. Rework on Solid Works PS Modeling according to revised design

9. Material Selection TS By using CES Material Selector 3.2 Demo

version in CAGIL lab.

10. Material Purchasing AS Make a list of materials required with

quantity and find out the probable vendors

By searching on internet.

11. Manufacturing PS It is to be done in Central Workshop

according to the specified dimensions.

12. Testing SN To be done on a car in different

environments.

13. Flaw removing GS In the process of testing if we are facing any

sort of problem regarding the functionality

than we will redesign that part to meet

requirements.

14. Rework AS Again it is to be done in Central Workshop.

15. Aesthetics TS Painting and finishing the product.

Gantt Chart:

Continued…

3.3.3.3. SKETCHES OF CONCEPTS

Design#1

Jack action as well as mobility of vehicle can be achieved.

Jack applied then vehicle raised- up then moved off the road and then

wheel can be changed.

For jack action rack and pinion mechanism is used.

Design#2

Jack action as well as mobility of vehicle is achieved.

Comprise of a bench vice type structure (jaws) to be fixed where jack is

to be applied then the vehicle is raised-up using jack then vehicle can

be moved and later on wheel can be changed. Jack action is performed

by screw as in normal car jacks.

Design#3

Only mobility is the motive.

Fast and easy applicability. Very compact size.

Jack is put in right position then lever rotated which moves the rollers

towards each other hence raising the wheel up.

Design# 4


This is not fast and easily applicable.

Wheel is required to be pushed over the plate then screws are

tightened which raise-up the plate then vehicle can be moved

Design#5


Compactness of size and fast applicability were other aspects.

First the wheel to be pushed on to jack then the two front and back

sliders were moved up and locked then the vehicle can be moved.

DESIGN ALTERNATIVES

1)Dominic method

HIGH PRIORITY

Reliability

Easy to use

Safety

works under extreme conditions

Cutting of tyre

MODERATE

Light Weight

Compactness

Distance it can travel(Range)

LOW PRIORITY

Durability

Low Maintanence

Cost

Design# HIGH MEDIUM LOW RANK

#1 P G F P E G G P G G G 2

#2 F F G F E F F F F G F 3

#3 G G G F F E G G G F F 1

#4 P P F P F F F F P P G 5

#5 F P P G F P F F G G G 4

High Moderate Low

Excellent (E)

1 2 3

Good (G) 1 3 3 3 5 1 1 3 3 1 1 1 2 3 4 5 5 5

Fair (F) 1 2 2 2 3 3 4 4 5 5 2 2 2 4 4 4 5 5 2 2 3 3

Poor (P) 1 1 4 4 4 5 5 1 5 4 4

Unacceptable (U)

2)Pugh's method

HIGH PRIORITY

Reliability - S + - S

Easy to use + S + - -

Safety S + + S -

works under extreme

conditions - S S - +

Cutting of tyre + + S S S

stability - S + S S

Should not come off easily - S + S +

MODERATE

Light Weight + S + S -

Compactness + S + S S

Time + S + - S

Distance it can travel(Range) - S + S S

Weight it can carry(Range) + + + S +

LOW PRIORITY

Durability + S + - +

Low Maintanence + + S - +

Cost + S S + +

Universal S S + + +

Speed of car - S + S S

Can it function as a jack + + - - -

TOTAL + 10 5 13 2 7

TOTAL - 6 0 1 7 4

TOTAL S 2 13 4 9 7

RANK 3 2 1 5 4

3)Pahl and Beitz

D1 D2 D3 D4 D5 W1 W2 W3 W4 W5

HIGH PRIORITY WEIGHT

Reliability 0.12 1 2 3 1 2 0.12 0.24 0.36 0.12 0.12

Easy to use 0.1 3 2 3 1 1 0.3 0.2 0.3 0.1 0.1

Safety 0.14 2 3 3 2 1 0.28 0.42 0.42 0.28 0.28

works under extreme

conditions 0.1 1 2 2 1 3 0.1 0.2 0.2 0.1 0.1

Cutting of tyre 0.14 4 4 3 2 2 0.56 0.56 0.42 0.28 0.28

MODERATE

Light Weight 0.08 3 2 4 2 1 0.24 0.16 0.32 0.16 0.16

Compactness 0.1 3 2 3 2 2 0.3 0.2 0.3 0.2 0.2

Distance it can travel(Range) 0.06 1 2 3 2 2 0.06 0.12 0.18 0.12 0.12

LOW PRIORITY

Durability 0.06 3 2 3 1 3 0.18 0.12 0.18 0.06 0.06

Low Maintanence 0.04 3 3 2 1 3 0.12 0.12 0.08 0.04 0.04

Cost 0.06 3 2 2 3 3 0.18 0.12 0.12 0.18 0.18

1

2.44 2.46 2.88 1.64 1.64

RANK

3 2 1 4 4

Conclusion: From the above analysis it is found that Design#3 is most

suitable and is fulfilling our aim to the required extent.

5) THE CHOSEN CONCEPT

Selected Design – A sketch

6. TRIZ Analysis

Principle 1. Segmentation

Divide an object into independent parts, make an object easy to disassemble.

• The handle to rotate the bolt is separated from the jack to reduce the overall size.

Principle 2. Taking out

Separate an interfering part or property from an object, or single out the only necessary part (or

property) of an object.

• Once the jack is installed there is no need of the handle and hence it is made detachable

otherwise it will obstruct the tyres of car.

Principle 3. Local quality

Change an object's structure from uniform to non-uniform

• Instead of designing a flat jack the design of the leaf part is non-uniform which has

additional advantages of support to main frame and accommodating big casters.

Principle 4. Asymmetry

A. Change the shape of an object from symmetrical to asymmetrical.

• The mechanism to slide the collars closer to each other is installed at the side of mainframe

rather than at the centre to ensure convenient operability.

Principle 6. Universality

Make a part or object perform multiple functions; eliminate the need for other parts.

• The jack is so designed that it can be used on roads as well as in homes and showrooms to

shift the vehicles from one place to other with less effort.

Principle 7. "Nested doll"

A. Place one object inside another; place each object, in turn, inside the other.

• In the main mechanism the two rectangular ducts are nested or mounted one inside the

other to facilitate the movement of collars.

B. Make one part pass through a cavity in the other.

• One of the rectangular ducts in the main mechanism moves in the cavity of the other.

Principle 8. Anti-weight

To compensate for the weight of an object, merge it with other objects that provide lift.

• The leaf part of the jack provides a lift to the main frame to compensate for its weight.

Principle 9. Preliminary anti-action

A. If it will be necessary to do an action with both harmful and useful effects, this action should be

replaced with anti-actions to control harmful effects.

• An additional rod is welded to give more strength to the mainframe.

B. Create beforehand stresses in an object that will oppose known undesirable working stresses

later on.

• The welded rod gives additional stress to the mainframe which counters the deformation

caused by the weight of the car on the mainframe part attached to the collars.

Principle 11. Beforehand cushioning

• The welded rods provide additional support to the jack in case the collars break the rods will

give support to the vehicle and prevents jerks.

Principle 12. Equipotentiality

Change the condition of the work so an object doesn’t need to be raised, lowered, rotated, etc.

• The casters provided in the jack avoid the manual rotation of the jack to change the

direction in case of turns.

Principle 13. 'The other way round'

Make fixed parts movable and movable parts fixed.

• Instead of sliding the bearing holding the collars the rectangular pipe along with the bearing

on it is made to move. This modification reduces effort , wear and tear and regular need of

maintenance.

Principle 14. Spheroidality – Curvature

Go from linear to rotary motion, use centrifugal forces.

• Spherical casters are used instead of cylindrical wheels to facilitate turning of the jack.

Principle 15. Dynamics

Allow (or design) the characteristics of an object, external environment, or process to change to be

optimal or to find an optimal operating condition.

• The distance between the collars is adjustable so as to ensure the operability of jack for

tyres of all specifications.

Principle 16. Partial or excessive actions

• The leaf (on which the casters are attached) instead of being strip are extended throughout

the two parts of mainframe for more support.

Principle 22. "Blessing in disguise" or "Turn Lemons into Lemonade"

• No support on the other side of the mainframe is a harmful effect on the strength and

capacity of jack but necessary for easy use. To compensate for this rods are welded below

the collars to give additional support but with disadvantage of using welding and hence

fixing it to mainframe but overall reliability of product increases.

Principle 25. Self-service

Make an object serve itself by performing auxiliary helpful functions

• The casters attached can easily rotate and temporarily change their direction when stuck by

an obstacle.

Principle 27. Cheap short-living objects

• Since the load is not directly on the leaf, the material of leaf can be different than that of the

main frame so as to reduce cost and avoid additional properties of the material which are of

not much importance for such a part.

Principle 33. Homogeneity

• The material of the bearings, rod and mainframe are the same because they play an

important part in the functioning and hence proper strength should be given which is

possible only if the welding is good and so the material should be same.

Principle 40. Composite Material

• Collars can also be made from composite material to meet the requirements.

7) PRODUCT SPECIFICATION

DIMENSION 480mm*900mm*195mm

WEIGHT 6kg

TYRE SIZE APPLICABLE TO 9inch-15inch wheel dia

WEIGHT APPLICABLE TO 550 kg

MAX SPEED 10 km\hr

COST Rs 4000

8) PRODUCT NAMEPLATE

MOBILE CAR JACK

MODEL NO: CJM202

MFG DATE: 12/04/08

PERFECT AUTOMOBILE SOLUTIONS

MADE IN INDIA

BOM AND MATERIAL SELECTION

9) BOM

1.

COMPONENT MATERIAL QUANTITY

1. COLLAR ALUMINA PARTICULATE, ALUMINIUM COMPOSITE 2

2. NUT/BOLT ZINC ALUMINIUM GENERAL CASTING ALLOY 1

3. FRAME ZINC ALUMINIUM SUPERPLASTIC ALLOY, 2

4. CASTER STANDARD, NYLON 6/6 42A NC010 4

5. HANDLE STANDARD 1

6. WASHER STANDARD 1

7. PILLOW

BEARING

STANDARD 4

8.DUCT1 ZINC ALUMINIUM SUPERPLASTIC ALLOY 2



10.BLOCK1 ZINC ALUMINIUM SUPERPLASTIC ALLOY 1

11.BLOCK2 ZINC ALUMINIUM SUPERPLASTIC ALLOY 1

10) MATERIAL SELECTION

1. COLLAR

REQUIRED PROPERTIES

A. HIGH COMPRESSIVE STRENGTH

B. MODERATE WEIGHT/DENSITY

C. LOW PRICE

D. HIGH FRACTURE TOUGHNESS

E. HIGH TENSILE STRENGHT

F. LOW WEAR

GRAPHS:

SELECTED MATERIAL

2. NUT/BOLT

REQUIRED MATERIAL

A. LOW WEAR

B. LOW PRICE

C. MAXIMUN TESILE STRENGTH

D. POSITIVE ENDURANCE

E. HIGH YOUNGS MODULUS

F. MODERATE DENSITY

GRAPHS

MATERIAL SELECTED

3. FRAME

REQUIRED PROPERTIES

A. LOW DENSITY

B. HIGH COMPRESSIVE STRENGTH

C. HIGH TENSILE STRENGTH

D. HIGH FRACTURE TOUGHNESS

E. LOW PRICE

GRAPHS

SELECTED MATERIAL

4. HANDLE OF JACK

REQUIRED PROPERTIES

A. LOW DENSITY

B. HIGH ENDURANCE LIMIT

C. HIGH FRACTURE TOUGHNESS

D. LOW PRICE

SELECTED MATERIAL

STANDARD QUALITY AVAILABLE IN MARKET

5. CASTER

REQUIRED PROPERTIES

A. HIGH COMPRESSIVE STRENGTH

B. WEAR RESISTANCE

C. HIGH ENDURANCE LIMIT

SELECTED MATERIAL

NYLON 6/6 42A NC010

STANDARD QUALITY AVAILABLE IN MARKET

12) POKA YOKEPOKA YOKEPOKA YOKEPOKA YOKE

Problems which we encountered while conceiving the mechanism for our product

and the remedies we provided to counter these problems in order to make our

product full proof. We had to analyse the product and figure out how it can be

cumbersome while usage. Then we included some counter provisions to eliminate

the problems posed, which is known as Poka yoke mechanism.

In our product some of the problem we envisaged were regarding

1. the enormous amount of force require to install the system under the

wheels

2. the threat of jack getting derailed

3. wear that may be incurred on the wheels

4. the system may came out while the vehicle negotiates a turn

PROBLEM 1

To install the jack we have to slide it beneath the car on the side of the wheel, and

then lift the wheel by bringing the collars together. This will require a large

amount of force and on the top of this we cannot use a gear system due to its

alignment problems

SOLUTION 1

In order to avoid the usage of gears, we employed a nut-bolt mechanism which is

based on a very simplistic theory; one of the two collars is attached to the end of

bolt while the other has the nut attached to it. Hence, by simply tightening the

bolt over the nut, the two collars can be brought together by applying a very

reasonable force.

PROBLEM 2

While the vehicle moves, there is a possibility that the jack gets derailed and

comes out of the vehicle, this may in turn prove catastrophic. It is also well

possible that the jack may fall down in some ditch on the roads.

SOLUTION 2

Since this a very serious threat so in order to forestall this, we used two collars

which will clutch the wheels tightly prevents any such mishappening. We used the

nut-bolt mechanism so that the clutch does not loosen at any point of time.

PROBLEM 3

As the wheel (driving) will continue to rotate even after installation of the jack, it

may lead to serious wear and tear of the tyre.

SOLUTION 3

To reduce the wear incurred on the tyre, we have used rotating collars, which will

rotate with the wheel. Thus, the tyre will not rub against the collar during motion

and it will increase the life ot the tyre.

PROBLEM 4

As the vehicle turns, it is probable that the system flies out due to the centrifugal

force acting on it unless we have some safety measures for it In such a case it may

lead to a disaster.

SOLUTION 4

To avoid such a mishappening, we have raised the frame on the side facing out of

the car so that even if the centrifugal force is high, it will not let the jack fly out.

Another thing we did was to put casters instead of wheels so that the jack may be

able to rotate freely with the vehicle while the turns.

12)12)12)12)CAD MODELS OF PARTS, SUBASSEMBLY AND ASSEMBLYCAD MODELS OF PARTS, SUBASSEMBLY AND ASSEMBLYCAD MODELS OF PARTS, SUBASSEMBLY AND ASSEMBLYCAD MODELS OF PARTS, SUBASSEMBLY AND ASSEMBLY

BLOCK 1 Block2

Bolt Caster Sphere

Collar Caster Edge

Duct1 Duct2

Duct 3 Handle

Key Part2-frame

Pipe Rod

Washer Part1 Washer Part 2

Caster washer assembly

Assembly Frame

MAIN ASSEMBLY

13) COMPONENT, SUB13) COMPONENT, SUB13) COMPONENT, SUB13) COMPONENT, SUB----ASSEMBLY AND ASSEMBLY ASSEMBLY AND ASSEMBLY ASSEMBLY AND ASSEMBLY ASSEMBLY AND ASSEMBLY

DRDRDRDRAWINGSAWINGSAWINGSAWINGS

MAIN ASSEMBLY

15) Reliability, durability and safety audit

The reliability and durability of the product can be ensured by the proper

selection of materials, design, manufacturing processes involved and rigorous

testing of the product.

Reliability, durability and safety is ensured by:

• Selection of material meeting the specific requirements for different parts

and their respective functioning.

• Finalizing the design after complete analysis and considering all the possible

failure modes and respective modifications.

• Choosing appropriate manufacturing processes which meet the design

specifications as well as produces parts with good strength and minimum

defects.

• Rigorous testing of the prototype should be carried out to ensure that the

final product meets all the requirements.

• Smoothening all the corners and edges after manufacturing.

• Proper material selection so that the product has the desired strength and

so not fails during operation.

In the design of jack the two sides are joined by welding two rods which gives it

additional strength to keeps the jack intact and countering the deformation under

weight.

The leaf is a continuous solid (rather than a strip) which gives a lifting force to the

whole frame so as to counter the load.

After calculation of approximate force on the jack materials of good strength,

tensile and compressive strength, durability, wear etc has been selected using

CES.

The two welded rods ensure that the jack can hold the load of car in case the

collars break.

16) PRODUCT RECYCLING

RECYCLING

The scraps or extra material which remains as waste is recycled. In this product our team is using

readymade bearings, casters, nuts and bolts so recycling of these is not our concern. We are using

aluminium alloys for making the frame. The scraps from that is to be recycled.

RECYCLING OF ALUMINIUM ALLOYS

Aluminium alloy is segreted and is thoroughly processed in furnaces where in it is checked for

impurities, metal content on the spectrometer. The chips deriving from the machining of semi-

finished aluminium products are very difficult to recycle by conventional methods due to their

elongated spiral shape, small size, surface contamination with oxides, machining oil, etc.A

process that converts the chips into powder through ball milling. The obtained powder was then

cold pressed and hot extruded, with and without ceramic particulates, to produce aluminium

alloys or aluminium matrix composites.Aluminium alloy chips were cold pressed at different

pressures to determine the compressibility curve. A floating cylindrical die with 25 mm of

diameter was used. The samples, previously cold pressed at 650 MPa, were submitted to hot

pressing at 500 °C in a cylindrical mould with graffito as lubricant. Two times and two pressures

were used to obtain the hot pressed samples, according to Table 1.

Table 1. Parameters used for the hot pressing

Hot extrusion was carried out at 500 °C; extrusion ratios were 6.25:1 and 25:1; graffito was

employed as lubricant. To evaluate the influence of the pressing condition on the properties of

the extruded materials, two kind of samples were extruded:

• cold pressed chips (650 MPa),

• hot pressed (500 °C, 700 MPa, 50 min) chips.

The hot consolidated materials were characterised by optical and electronic microscopy, energy

dispersion spectrometry (EDS). Hot extruded materials were also characterised by ultimate

tensile strength (UTS).

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