Professional Documents
Culture Documents
2011/2012 SESSION
1
CERTIFICATION
We the undersigned hereby certify that this project was carried out by
the under listed students.
____________________________
____________________________
OKECHUKWU NNAMDI
FPI/HND/MEC/010/004
____________________________
ENEJIYON ABDULMALEEQ
FPI/HND/MEC/010/009
____________________________
AGONOR WILLIAMS
FPI/HND/MEC/010/019
____________________________
I certify that the work is adequate in scope and quality for the partial
fulfillment for the award of Higher National Diploma (HND) in Mechanical
Engineering.
___________________________
ENGR. O. Y. USMAN
Head of Department
_______________________
MR. BINGFA BONGFA
Supervisor
APPROVAL PAGE
This project work titled design and construction of hydraulic scissors lift
has been read and approved as meeting the requirement of the national
Board for Technical Education (NBTE) for the award of Higher National
Diploma (HND) in the department of Mechanical Engineering, Federal
Polytechnic Idah, Kogi State.
__________________________
MR. BINGFA BONGFA
Project Supervisor
________________________
External Examiner
Date ______________________
Date ____________________
_________________________
ENGR. O.Y. USMAN
Head of Department
DEDICATION
We dedicated this project to the Almighty God who spare our lives to this
day and make this project a reality.
ACKNOWLEDGEMENT
ABSTRACT
TABLE OF CONTENT
Title Page -
Certification -
ii
Approval page -
iii
Dedication -
iv
Acknowledgement - -
Abstract - -
vi
Table of content-
vii
CHAPTER ONE
1.0 Introduction -
2.2 Scaffold -
CHAPTER TWO
10
11
12
22
22
23
23
24
25
27
33
CHAPTER FOUR
4.0 Material Selection, Construction Procedures, Cost Analysis and
Maintenance
41
41
46
49
CHAPTER FIVE
5.0 Conclusion and Recommendation - -
50
5.1 Conclusion - -
50
5.2 Recommendation - -
50
Reference -
52
CHAPTER ONE
1.0
INTRODUCTION
A scissor lift or mechanism is a device used to extend or position a
11
13
CHAPTER TWO
2.0
Mans quest for improvement has never been satisfied. The drive
towards better and greater scientific and technological outcome has
made the world dynamic. Before now, several scientist and engineers
have done a lot of work as regards the scissors lift in general. A review of
some of that work gives the design and construction of a hydraulic
scissors lift a platform.
2.1
14
1986, they had introduced their first sigma arm lift, model SL20. In 1990,
they improved upon their product line by introducing the sigma arm
speed level. This feature continued to be unique to be upright product
and allow self-leveling of the platform on rough terrains
Upright introduced an equal innovative family of boom lift in 1990s. In
1995 they produced their first trailer mounted boom. The 8P37 (known
as AS38) in 1996. This truly innovated company has left their mark with
the other products including compact scissors design and modular alloy
bridging, as well as expanding the versatility of instant span towers with
aircraft docking and faced system, you will find upright products,
especially the scissors lift, as standard equipment for a variety of
application it is now a visual application in numerous fields and locations.
[www.carliftequipment.ca/inventory/upright]
2.2
SCAFFOLD
15
worker
can
stand
comfortable
on
top.
[http://en.m.wikipedia.org/wiki/scaffold]
2.3
BOOM LIFT
Boom lifts are used for lifting materials especially on construction sites,
they are designed to carry heavy equipment and materials from one
16
place to another. They are usually connected to cars or trucks that move
from one place to another.
Boom lifts can lift materials and equipment high to height so great that
carrying this equipment by other means will almost be impossible.
According to material handling equipment from ask search engine,
Boom lifts can move vertically, horizontally and sideways and some can
even rotate depending on the circumstance. Boom lifts are very complex
iron design and the jointed parts should be lubricated to reduce friction
and improve efficiency. Boom lifts are formed mainly in construction sites
and building sites. They are also utilized by Electrical companies and
firms such as PHCN (Power Holding Company of Nigeria) Plc. They are
very expensive and are not available in crude or semi mechanized type
of production. Boom lift possess advantage over other types of lifts
because it can lift heavy materials, keep them at elevated heights for a
long period of time; rotate and the lift span of the equipment is long.
Boom lift can fold together to become compressed and portable.
There are two basic types of boom lifts: straight boom lift and articulated
boom lift. These units are often hydraulically powered.
2.3.1 THE STRAIGHT BOOM LIFTS
Straight boom lifts are generally used for jobs that required a high reach
without obstruction. The machines turntable can rotate 360 o with an
17
lead screw. This can be used to lift the working and equipment to a
height.
A general knowledge however, regarding screws will reveal the loss due
to friction in the screw threats. Therefore, the efficiency of this device is
low due to losses in friction. Also, the power needed to drive the machine
is manual, and much energy is expanded to achieve a desired result. Its
suitability however, cannot be overemphasized as it can be used in
almost every part of the country whether there is availability of electricity
or not.
2.5
HYDRAULIC LIFT:
Hydraulic lift is a device for carrying persons and loads from one floor to
another, in a multi-storey building. The hydraulic lifts are of the following
types.
1.
2.
19
20
2.5.2 PRINCIPLE
OF
OPERATION
OF
HYDRAULIC
LIFT
21
22
Scissors Legs
Leg deflection due to bending is a result of stress, which is driven by
total weight supported by the legs, scissors leg length, and available leg
cross section. The longer the scissors legs are, the more difficult it is to
control bending under load. Increased leg strength via increased leg
material height does improve resistance to deflection, but can create a
potentially undesirable increased collapsed height of the lift.
Platform Structure
Platform bending will increase as the loads center of gravity moves from
the center (evenly distributed) to any edge (eccentrically loaded) of the
platform. Also, as the scissors open during raising of the lift, the rollers
roll back towards the platform hinges and create an increasingly
unsupported, overhung portion of the platform assembly. Eccentric loads
applied to this unsupported end of the platform can greatly impact
bending of the platform. Increased platform strength via increased
support structure material height does improve resistance to deflection,
but also contributes to an increased collapsed height of the lift.
Base Frame
Normally, the lifts base frame is mounted to the floor and should not
experience deflection. For those cases where the scissors lift is mounted
to an elevated or portable frame, the potential for deflection increases.
To effectively resist deflection, the base frame must be rigidly supported
23
from beneath to support the point loading created by the two scissors leg
rollers and the two scissors leg hinges.
Pinned Joints
Scissors lifts are pinned at all hinge points, and each pin has a running
clearance between the O.D. of the pin and the I.D. of its clearance hole
or bushing. The more scissors pairs, or pantographs, that are stacked on
top of each other, the more pinned connections there are to accumulate
movement, or deflection, when compressing these running clearances
under load.
Hydraulic Circuit Air Entrapment
All entrapped air must be removed from the hydraulic circuit through
approved bleeding procedures air is very compressible and is often
the culprit when a scissors lift over-compresses under load, or otherwise
bounces (like a spring) during operation.
Hydraulic Circuit Fluid Compressibility
Oil or hydraulic fluid will compress slightly under pressure. And because
there is an approximate 5:1 ratio of lift travel to cylinder stroke for most
scissors lift designs (with the cylinders mounted horizontally in the legs),
there is a resulting 5:1 ratio of scissors lift compression to cylinder
compression. For example: 1/16 of fluid compressibility in the
cylinder(s) translates into 5/16 of vertical lift movement.
24
scissors) are usually shared well between the two scissors leg pairs.
Side loads (perpendicular to the scissors), however, are not shared as
well between the scissors leg pairs and must be kept within acceptable
design limits to prevent leg twist (unequal scissors leg pair deflection)
which, in addition to platform movement due to deflection, often results
in poor roller tracking, unequal axle pin wear, and misalignment of
cylinder mounts.
Lift Elevation During Transfer
As mentioned above, degree of deflection is directly related to change in
system pressure and change in component stress as a result of loading
and unloading. Scissors lifts typically experience their highest system
pressure and highest stresses (and therefore the highest potential for
deflection) within the first 20% of total available vertical travel (from the
fully lowered position).
What can be done to Limit Deflection?
There are a variety of proven methods to reduce scissors lift deflection,
with varying design and cost impacts to accomplish each. Listed below
are the most common of these methods, in no particular order, to
provide the reader an understanding of where to begin when attempting
to reduce or eliminate deflection during load transfer (i.e. applying a
load, or removing a load).
26
Select a Lift with a Design Capacity Greater Than Required for the
Application
Most scissors lifts designed for duty at higher capacities will experience
less stress in all structural components, as well as lower system
pressures, at lower, or de-rated, working capacities. Reduced stresses &
pressures always result in reduced deflection. The amount of this
reduction varies depending on the lifts design, so consult the
manufacturer to obtain a more specific estimate of reduction in
deflection.
Minimize Potential for Air Entrapment
Scissors lift manufacturers provide an approved method of bleeding
entrapped air from a new or repaired hydraulic system which may have
had air introduced. This usually involves operating an empty lift through
multiple cycles, and then safely cracking open fittings near high spots in
the system where air accumulates. Refer to the O&M manual for this
procedure.
Limit or Eliminate Hosing
Flexible hose lengths should be limited wherever possible and replaced
with pipe or mechanical tubing as practicable to minimize or eliminate
swell as the system pressure fluctuates.
Use Mechanical Actuators in lieu of Hydraulic Actuators
27
28
Ensure that the Base Frame is Lagged Down and Fully Supported
First, base frames should be adequately attached to the surface on
which they are mounted. Base frames that are not bolted, welded, or
otherwise attached to withstand the upward forces created by eccentric
loading of the platform will contribute to deflection by bending or moving
while resisting such forces. Next, bases must be rigidly supported
beneath the entire perimeter of the frame in order to withstand without
deflection the four point loads imposed upon the frame from above by
the four scissors legs (2) moving roller points and (2) fixed hinge
points.
Platform Locking Pins
When there is no alternative to transferring loads over the sides of a lift,
or whenever lift deflection must be held to near zero in any transfer
orientation, consider using platform locking pins. These pins can be
manual or powered, and mounted beneath the scissors lift deck or an
adjoining fixed landing. The pins are extended into receivers located in
the mating elevated structure during load transfer, and then retracted
before the lift can be operated again.
Use Vertical Acting Actuators in lieu of Horizontal Mounts
Some permanent installations may accommodate actuators which are
mounted vertically beneath the lift instead of horizontally inside the lift
structure. Vertical orientation of the actuators provide a 1:1 ratio of lift
29
travel to actuator stroke instead of the 5:1 ratio normal with horizontal
mounting of the actuators inside the scissors. This means a 1:1 ratio of
lift deflection to actuator compression, 80% less than the 5:1 ratio
experienced normally. Vertical mounting and pushing upward against
underneath side of the platform to raise the lift also eliminates the high
stresses usually exerted at the actuator thrust inner leg member(s).
Summary on Deflection
Deflection is a normal and expected characteristic of industrial scissors
lifts. And though odds are that most scissors lift users have not had to
concern themselves with this issue because their lifting application is
fairly immune to the effects of deflection, there is always a chance that it
matters greatly. ANSI MH29.1accurately points out that It is the
responsibility of the user/purchaser to advise the manufacturer where
deflection may be critical to the application. Though deflection is easier
to qualify than it is to quantify, there are industry best practices which
can be applied to reduce the impact or amount of deflection being
experienced.
(Michael, 2008)
30
CHAPTER THREE
3.0
DESIGN THEORY
In this chapter, mathematical relationships are developed for the
31
upon the flow rate, the pressure drop a cross the actuator and its overall
efficiency.
Most lifting devices are powered by either electricity, pneumatic or
mechanical
means. Although
these
methods
are
efficient
and
Single acting cylinders use hydraulic oil for a power stroke in one
direction only. The return stroke is affected by a mechanical in one
direction only. The return stroke is affected by a mechanical spring
32
located inside the cylinder. For single acting cylinders with no spring,
some external actin force on the piston rod causes its return.
3.1.1.2
P=F
A
F = [W + (WA)]
2_
tan
33
a The strength of the rod. i.e its ability to support a specified load
without experiencing excessive stresses
b The ability of the piston to support a specified load without
undergoing unacceptable deformations.
PE
2EI
L2
= d4
64
(Rajput, 2010)
= AK2
I_
A
Note that the smallest radius of gyration of the column, i.e the least
moment of inertia I must be taken in order to find the CRITICAL STESS
OR BUCKLING STRESS OR CRIPPLING STRESS.
34
= PE
A
= 2E_
(L/k)2
Where
E = is the compressive stress in the column and must not exceed the
yield stress Y of the material i.e E < Y
L/K is called the SLENDERNESS RATIO; it is a measure of the columns
flexibility.
CASE END CONDITIONS
EQUIVALENT
BUCKLING
LENGTH Le
L
LOAD (EULER)
2EI
2L
L2
2EI
free
One end fixed other end
L/ 2
4L2
22EI
pin jointed
Both ends fixed or
L/2
L2
42EI
encastered
L2
(Rajput, 2010)
(Rajput, 2010)
Bearings
-
Platform
-
Jointed Members
- Thickness of rectangular pipe = 3mm
- Thickness of angle bar = 3mm.
Scissors Arm
The material used for the scissors arms (members), is stainless steel.
With the density and the dimensions of the scissors arms known,
the mass can be calculated using the relationship.
Density (p) = Mass (M)
Volume
Mass = p.v
kg/m3
X
t
Section X - . - - X
38
Actuator
F
W + Wf
2
W + Wf
2
F = W + Wa
2tan
Where
39
Psin = (W+WF)
2
P = [(W+WF)/2sin]
F = Pcos
F = cos [(W+WF)/2sin]
F = (W+WF)/2tan
40
A = 216MM2
L = 1200MM
stainless steel
Processing
A1 = b h
= 25 50
A2 = (b t)(h t)
= (25 3)(50 3)
= 22 47
Output
A1 = 1250m2
A = A1 A2
= 1250 1034
A = 216mm2
V =A L
= 216 10-6 120010-3
V = 2.5910-4m3
A2 = 1034M2
7900Kg/M3
M = PV
V = 2,59 10-4 M3
= 7900 2.54 10-4
M = 2.05Kg
Mass of one tier = M 4
= 2.05 4
M = 2.05kg
8.2kg
Ms = 8.2Kg
g = 9.81M/s2
Mp = 300Kg
g = 9.81M/s2
WA = 80.4N
= 500
Wa = Msg
= 8.2 9.81
W = 80.4N
41
F=
WA
2
tan
W+
W = 2943
F 2503.1N
W= Mpg
= 300 9.81
F
80.4
2
2943+
tan 50
2943+
Foverall = 7509N
= 7.5kN
40.2
1.1918
Foverall = 2503.1 3
HYDRAULIC CYLINDER
CALCULATION
Selected cylinder diameter from
standard cylinder sizes
D=36
D=50
A1=D 2/4
= 502/4
A1 =1963.5mm2
A2=/4[D2-d2]
=/4[502-362]
A2=945.6mm2
F=7.5KN
Supplied pressure
A=1.963510-3m2 P=F/A
=7.5103/1.963510-3
DESIGN OF CYLINDER FOR
BUCKLING
For both ends pinned,
Buckling load
PE =2EI/L2
42
P=38.20bar
L=0.8m
E=210GN/m2
(for mild steel)
D = 0.036m
I=d4/64
I=(0.036)4/64
I=8.2410-8m4
PE =22101098.2410-8/0.82
A=
PE = 267004.7N
D = 0.036
d2
4
2
0.036
Buckling stress
E
267004.7 3
10
1.02
PE=267KN
A = 1.0210-3m2
d = 0.036
L = 0.8m
SLENDERNESS RATIO
Radius of gyration
d
K 4
K = 0.009
0.036
4
Slenderness Ratio =
3.5.2.2
P = 38.2 bar
D = 50mm
t = 5mm
E = 262Mn/m2
L
K
= 89
long column
0.8
0.009
Pd
2t
c=19.1MN/M2
3.83 1 0 50 1 0
3
2 5 1 0
P = 38.2 bar
D = 50mm
t = 5mm
Longitudinal stress
Pd
L 4 t
44
L = 9.55mn/m2
103
3.82 10 50
5 103
4
6
L = 450mm
D = 50mm
P = 38.2 bar
16
9
60mm
Head
body
thread
F = 750
d = 9mm
Area of pin
Ap = dp2/4
(9 10-3)2 / 4
= 22/7
r = 0.045m
h = 0.06m
45
Ap = 6.3610-5m2
As = 2.969 10-2
= 118mn/m2
cr = 253kn/m2
load
sruface area
total
7509
10 x 2
2.969
b
B
B = 50mm
D = 25mm
T = 3mm
b = B t = 50 3
d = D t = 25 3
I =B D3
b = 47mm
d = 22mm
b d3
12
I = 2.34 10-8m2
22 3 /12
25 347
50
= 22/7
E = 193 109
I = 2.34 10-8
L = 1.2m
A = 216mm2
2 EI
L2
2 193 109
PE = 37.144kN
8
2.341 o
1.2
Critical stress
E = 172MN/M2
46
l 2
k
2 E /
P
E
A
1.2 2
k
2 193 109 /
37.144
10
106
216
F
0.6m
0.6m
47
W+WF/2
W=2943N
WF=20.111N
M = force perpendicular
0
distance.
For = 100 ,
Bending moment =(W+WF/2)cos0.6
+W/2cos0.6
=0.6cos(W+WF/2 + W/2)
= 0.6 cos10(2943+20.111/2 +2943/2)
=0.60.9848(2953.06).
=1744Nm
FOR =200
Bending moment= 0.6cos(W+WF/2
+W/2)
=0.6cos20(2943+20.111/2 +2943/2)
=835.331 +829.661
=1664.99Nm
FOR =300
Bending moment= 0.6cos(W+WF/2 +w/2)
48
=0.6cos30(2943+20.111/2 +2943/2)
=769.84 + 764.59
FOR =400
=1534.43Nm
FOR =500
=1357.23Nm
Bending moment = 0.6cos(W+WF/2
+W/2)
= 0.6cos50 (2943+20.111/2 +2943/2)
=0.38572953.06
M/I=/Y=E/R
Therefore from the analysis of the bending
moment above, the Maximum bending
moment = 1744.92Nm occurs at the point
when =100
Therefore, the smaller the angle, the
higher the bending moment and vis-visa.
49
=1138.91Nm
CHAPTER FOUR
and the material for the machine depends on the particular purpose and
the mode of operation of the machine components. Also, it depends on
the expected mode of failure of the components.
Engineering materials are mainly classified as:
1 Metal and their alloys, such as iron, steel, copper, aluminum etc.
2 Non-metals such as glass, rubber, plastic etc. metals are further
classified as ferrous metals and non-ferrous metals.
Ferrous metals are those metals which have iron as their main
constituent, such as cast iron, wrought iron and steels.
Non-ferrous metals are those which have a metal other than iron as
there main constituent, such as copper, aluminum, brass, tin, zinc etc.
For the purpose of this project, based on the particular working
conditions machine component were designed for only the ferrous
metals have been considered.
Also, certain mechanical properties of metals have greatly
influenced our decisions. These properties include:
1 Strength: it is the ability of a material to resist the externally applied
force without break down or yielding the internal resistance offered
without break down or yielding the internally applied force is called
stress.
2 Stiffness: it is the ability of a material to resist deformation under stress.
3 Elasticity: it is the property of a material to regain its original shape after
deformation when the external force are removed.
51
4.
52
Scissors arms
Hydraulic cylinder
Top plat form
Base plat form
Wheels
to
internal
compressive
pressure
which
generates
53
Base Platform: this component is subjected to the weight of the top plat
form and the scissors arms. It is also responsible for the stability of the
whole assembly, therefore strength. Hardness and stiffness are needed
mechanical properties. Mild steel is used.
Wheels: the wheels are position at the base part of the scissors lift and
enable the lift to move from one place to the other without necessary
employment of external equipment like car.
Choice of stainless and mild steel
1
Mild Steel contains 0.05 to 0.3 percent carbons it has for almost all
purpose replaced wrought iron, its greater strength giving it under viable
advantages. Mild steel can be rolled, wielded and down. It can even be
cast, though not very successfully. Among its application are plates for
ship building, bicycle frame tubes, mesh work, bolts, nuts, studs etc.
solid and hollow constructional sections, sheet metal parts and steel
54
considered to meet all requirements and the choice of stainless steel for
the scissors members.
Marking out
Cutting
Drilling
Joining (welding and bolt and nut)
Tools
1 Engineers rule
2 Scriber
3 Hack saw
4 Hand file
5 Drilling machine
6 Welding machine
7 Pliers
8 spanner
9 Try square
10 Electric grinder
Construction Procedure
1 Base Platform the material used for this purpose is mild steel angle bar.
(33 inch) thickness 3mm. this is used because the base frame is
55
responsible for the stability of the platform. The basic dimensions were
marked out using on Engrs rule and scriber and then cut with the use of
hack saw after being welded firmly clamped to the vice. They are then
joined together by welding to give the base frame.
2 Scissors Arms these include the members that are arranged in a crosscross X pattern and whose construction is responsible for lifting the
platform and extension and lowering of the platform.
It is usually made up of pipes with rectangular cross-section and have
high resistance to bending. The material is stainless steel for corrosion
and rust resistance to give high strength.
After marking out, they were cut to the required sizes holes of
appropriate diameter were drilled at both ends and the middle of each
member. Hollow pins of external diameter corresponding to the drilled
holes we then fit into holes and welded in order to strengthen the
position then joined together to give the X pattern using bolts and nuts.
The scissors arms were brazed to increase the strength and bending
resistance.
Top Platform
The material used for the construction of this component is mild steel
angle bar for the frame and timber for the base of the platform. The
56
angle bar is cut into the required sizes and welded to form a rigid
platform. The timber was equally into the required dimensions, drilled at
the edges and fastened using bolt and nut to secures it in position at the
base of the platform.
Assembling of various components of the hydraulic scissors lift.
The scissors assemblage was mounted on the base frame with
one end hinged and the other fitted with roller (bearing) to produce the
needed motion of rolling along the rail to cause lifting and lowering of the
scissors lift. The scissors arm connected to the platform is also
connected with one end hinged and the other fitted with roller to effect
extension and contraction of the lit. The hydraulic cylinder is connected
to the first arm of the scissors lift with both ends hinged. This cylinder
provides the force needed to lift the load on the platform.
The force is as a result of the pressure of the hydraulic supplied to the
cylinder by the pump from the reservoir.
The lift is fitted with wheels to aid mobility from one location to
another.
Painting of the entire unit is done to improve it aesthetics and
increase the corrosion and resistance to rust.
COST ANALYSIS OF MATERIAL
The table below shows the cost of material used in constructing the
hydraulic scissors lift
57
NO.
OF MATERIAL
QUANTITY
UNIT COST
TOTAL COST
ITEM
1
DESCRIPTION
REQUIRED
3 x 3 lnch Angular 3
2400
7200
2
3
bar
1 x 1 Inch Angle bar
8
1 x 2 inch stainless 8
1000
3000
300
30, 400
4
5
steel pipe
Mild steel bushins
20
Stainless
steel 13
50
100
1000
1500
6
7
electrode
Mild steel electrode
20
Drilling of stainless 12
25
250
500
3000
steel pipe
Stainless steel drive 2
250
500
9
10
11
12
bit
Bolt and nut
Wood timber
Roller bearing
Hydraulic
cylinder
25
650
100
6500
1000
1300
400
6500
13
(Ram)
Electric motor and 1
20, 000
20, 000
14
pump
Directional
control 1
5000
5000
2500
10, 000
6000
2000
96, 600
15
16
17
valve
Wheel
Transportation
Miscellaneous
TOTAL
40
3
4
1
CHAPTER 5
CONCLUSION
The design and fabrication of a portable work platform elevated by
which is operated by a motor. The scissor lift can be design for high load
also if a suitable high capacity hydraulic cylinder is used. The hydraulic
scissor lift is simple in use and does not required routine maintenance. It
can also lift heavier loads. The main constraint of this device is its high
initial cost, but has a low operating cost. The shearing tool should be
heat treated to have high strength. Savings resulting from the use of this
device will make it pay for itself with in short period of time and it can be
a great companion in any engineering industry dealing with rusted and
unused metals.
5.2
RECOMMENDATION
This device affords plenty of scope for modifications for further
59
REFERENCE
60
61