APPENDIX- 1.

STUDY AND REQUERENT OF AUTO ELECTRIC JACK A PROJECT REPORT

Submitted by

Mahesh Patidar Nandkishor Prajapati Sanjay Patidar Sunil Patidar

in partial fulfillment for the award of the degree of BACHELOR OF ENGINEERING

MECHANICAL ENGINEERING

MANDSAUR INSTITUTE OF TECHNOLOGY, MANDSAUR (M.P.) 458001 DEC. 2011

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DECLARATION
I hereby declare that the project entitled AUTO ELECTRIC JACK submitted for the B.E. Degree is my original work and the project has not formed the basis for the award of any degree, associate ship, fellowship or any other similar titles.

Signature of the Student:

Place:- Mandsaur Date:-

CERTIFICATE This is to certify that the project entitled AUTO ELECTRIC JACK is the confide work carried out by Mahesh Patidar, Nandkishor Prajapati, Sanjay Patidar, Sunil Patidar student of B.E., MANDSAUR INSTITUTE OF TECHNOLOGY, MANDSAUR, during the Final Year in partial fulfillment of the requirements for the award of the Degree of Bachelor of Engineering in Mechanical Engineering and that the project has not formed the basis for the award previously of any degree, diploma, associate ship, fellowship or any other similar title.
Signature of the Guide:

Place: - Mandsaur
Date:-

ACKNOWLEDGEMENTS
I take immense pleasure in thanking Prof. M.K. Ghosh for having permitted me to carry out this project work. I wish to express my deep sense of gratitude to my Internal Guide, Mr. Lalit Yadav for her able guidance and useful suggestions, which helped me in completing the project work, in time. Words are inadequate in offering my thanks to the Project Trainees and Project Assisatants, NCSI for their encouragement and cooperation in carrying out the project work.

Finally, yet importantly, I would like to express my heartfelt thanks to my beloved parents for their blessings, my friends/classmates for their help and wishes for the successful completion of this project.

Mahesh Patidar Nandkishor Prajapati Sanjay Patidar Sunil Patidar

ABSTRACT
The work in this study is in general described, an electrically operated car jack. A scissor type, automatically operated by switch buttons consists of a base, a load engaging head, gearing system and stabilizer base. The prototype includes motor powered from the cigarette lighter adapter. The motor with gearing system will be the lifting mechanism. When the car needed to be lifted, just press the button and release the button at a desired height level. The common problem faced by the current available car jacks in the market is it is manually operated and needed physical effort to lift the vehicle. All the analysis and results such as the torque needed and gearing ratio is important in this project before needed to be developed. The developed automatic car jacker is base on the result and analysis part to lift a Kancil car (682kg). The stress and Von Mises stress are additional analysis on the gearing parts to know how much stress applied on the system to avoid failure. The developed automatic car jacker is a success which it able to lift a kancils car according to the set scopes.

APPENDIX- 2. TABLE OF CONTENTS

Chapter
ACKNOWLEDGMENT ABSTRACT TABLE OF CONTENTS LIST OF FIGURES LIST OF TABLES 1 1.0 INTRODUCTION 1.1 JACK

Description

Page No. i ii iii v vii

1.2 PRODUCT SPECIFICATIONS

2.0 PROBLEM DEFINITION

2.1. PROJECT MOTIVATION

2.2. OBJECTIVE

2.3. BACKGROUND
2.4. SCOPE OF WRK 2 3.0 METHODOLOGY 3.1. GENERAL

3.2. DESIGN 3.2.1. These terms are defined as follows 3.3. SERVICE 3.4. INSPECTION, MAINTENANCE, AND CLEANING 3.5. SPECIFIC SAFETY RULES 3.6. To operate the Scissor Jack using the DC Plug 3
4.0 CONCLUSION AND FUTURE WORK 4.1 Conclusion 4.2 Scope For Future Work REFERENCES

CHAPTER-1
1. INTRODUCTION 1.1.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. PROJECT SPECIFICATIONS Electrical Requirements 12 VDC Via Cigarette Lighter Plug or Battery Clamps F6A250V (Fast-acting 6 Amp, 250 Volt) 2 Button Remote w/4 6 Control Cable 9 7 2 Tons (at 10 or higher) 43/4 w/Automatic Stop @ 43/4 131/2 w/Automatic Stop @ 131/2 2-1/2 Diameter x 5/8 Thick 1/2

Fuse Type

Control Unit Type

Power Cord Length Maximum Lifting Capacity Minimum Unit Height Maximum Lifting Height Lift Saddle Dimensions Lift Screw Diameter

Base Dimensions Overall Dimensions Accessories

Weight

8-5/8 L x 5 W x 1-1/2 H 15-1/2 L x 6-1/4 W x 4 H Spare Fuses (Qty. 3) / Manual Crank / 12 VDC Cigarette Lighter Plug Carrying Case / 12 VDC Battery Clamps (Qty. 2) 12 Pounds

2.0PROBLEM DEFINITION
Available jacks present difficulties for the elderly, women and are especially disadvantageous under adverse weather conditions. These presently available jacks further require the operator to remain in prolonged bent or squatting position to operate the jack. Doing work in a bent or squatting position for a period of time is not ergonomic to human body. It will give back problem in due of time. Moreover, the safety features are also not enough for operator to operate the present jack. 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. Furthermore, available jacks are typically large, heavy and also difficult to store, transport, carry or move into the proper position under an automobile. Suppose car jacks must be easy to use for pregnant women or whoever had problem with the tire in the middle of nowhere. The purpose of this project is to encounter these problems. An electric car jack which has a frame type of design by using electric from the car lighter will be developed. Operator only needs to press the button from the controller without working in a bent or squatting position for a long period of time to change the tire. 2.1 PROJECT MOTIVATION An automotive jack is a device used to raise all or part 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 to have in our vehicle due to unknown upcoming event such as flat tire in our journey. Even so, people who like to rotate their tires themselves or who may install snow tires before the winter and remove them in the spring need to use a jack to perform the job. Changing a flat tire is not a very pleasant experience. Moreover, the USMA report on the Integration and Performance of Women at West Point in Proceedings (July 1998) reveals sex-norming schemes whereby women. Navy studies show that only 12% of women can accomplish the two-person stretcher carry, a requirement critical to ship security. Women may be able to drive a five-ton truck, but need a man's help if they must change a tire. Women have a much lighter skeleton that means, among other things, she cant pull more forces as well as men and are at greater risk of skeletal injuries. Usually the car purposely tries to get a flat tire at the least opportune moments.

Like when you are rushing home from work, something emergency, business meeting or in the middle of the woods for instance. You are not going to be able to keep driving, so you are going to have to remove it and install your car's spare tire in its place. This is a waste of time and even will endanger you if you are jacking and changing the tire in car. 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. 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. With the spare installed, you should be able to reach your house or the nearest service station. 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. 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.

2.2. OBJECTIVES In order to fulfill the needs of present car jack, some improvement must be made base on the problems statement: 1. To design a car jack that is safe, reliable and able to raise and lower the height level. 2. To develop a car jack that is powered by internal car power and fully automated with a button system. 2.3.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. Such jacks present difficulties for the elderly and handicapped and are especially disadvantageous under adverse weather conditions. Furthermore, available jacks are typically large, heavy and also difficult to store, transport, 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. Suppose car jacks must be easy to use for pregnant women or whoever had problem with the tire in the middle of nowhere. In light of such inherent disadvantages, commercial automobile repair and service stations are commonly equipped with large and hi-tech car lift, wherein such lifts are raised and lowered via electrically-powered systems. However, due to their shear size and high costs of purchasing and maintaining electrically-powered car lifts, such lifts are not available to the average car owner. Engineering is about making things simpler or improving and effective. Such electrical-powered portable jacks not only remove the arduous task of lifting an automobile via manuallyoperated jacks, but further decrease the time needed to repair the automobile. Such a feature can be especially advantageous when it is necessary to repair an automobile on the side of a roadway or under other hazardous conditions. 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 is fails to work after 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, Ms Rankine has 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 doesnt meet the labeling or performance requirements of the Australian Standard for vehicle jacks.

2.4. SCOPES OF WORK

1. The developed automatic car jack can only withstand below 1000kg of load (Kancil 682kg) II. The developed automatic car jack must be operated on a flat surface. III. The developed automatic car jack is only a prototype and not readily functioning as commercial product. IV. The design is based on current scissor jack in the market. V. The developed automatic car jack is only for normal person. VI. The developed automatic car jack can only work by using the internal car power (12V)

CHAPTER-2 3.0 METHODOLOGY

3.1. GENERAL In this section, all the terminology on this project is presented.

Figure (A): Typical scissors jack 3.2.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. 3.2.1. These terms are defined as follows: 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. VI. Manufacturable: 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

begin by identifying exactly how to recognize a satisfactory alternative, and how to distinguish between two satisfactory alternatives in order to identify the better. From this, optimization strategies can be formed or selected. 3.2.1. Then the following tasks unfold: Invent alternative solution Establish key performance metrics Through analysis and test, simulate and predict the performance of each alternative, retain satisfactory alternatives, and discard unsatisfactory ones. Choose the best satisfactory alternatives discovered as an approximation to optimality. Implement the design The characterization of a design task as a design problem can introduce the idea that, as a problem, it has solution. 3.3. SERVICE 1. Tool service must be performed only by qualified service technician. Service or maintenance performed by unqualified personnel could result in a risk of injury.
2. When servicing the Scissor Jack, use only identical replacement parts. Follow instructions in the

Inspection, Maintenance, And Cleaning section of this manual. Use of unauthorized parts or failure to follow maintenance instructions may create a risk of injury. 3.4. INSPECTION, MAINTENANCE, AND CLEANING 1. Before each use, inspect the general condition of the Scissor Jack. Check for cracked, worn or damaged parts, loose or missing parts, and any other condition that may affect the tools safe operation. If a problem occurs, have the problem corrected before further use. Do not use damaged equipment.
2. To clean, use a damp cloth and a mild detergent. Do not use solvents or other flammable agents

3.

When storing, keep the Scissor Jack in a clean, dry, safe location out of reach of children and other unauthorized people.

4. To replace the Fuse: A melted wire strand within the Fuse (29) indicates the Fuse has blown and must be replaced. To replace the Fuse, unscrew the cap on the DC Plug (33) and remove the blown Fuse. Then, insert a new Fuse (type: F6A250V) in the DC Plug and replace the cap. (See Assy. Diagram.)

Figure (B):- Simple diagram of jack.

5. All maintenance, service, and repairs not discussed in this manual should only be performed by a qualified service technician.

3.5. SPECIFIC SAFETY RULES

1. Maintain labels and nameplates on the Scissor Jack. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 2. Use the right product for the job. There are certain applications for which this product was designed. Do not use this product for a purpose for which it was not intended. 3. Store idle tools. When not in use, store the Scissor Jack in a clean, dry, safe location out of reach of children. 4. Prior to using this product, make sure to read and understand all instructions and safety precautions as outlined in the vehicle manufacturers manual. Always make sure the vehicles weight is within the lifting capacity for the height that this Scissor Jack is used at. Use the Scissor Jack only on vehicles whose frames have seams capable of aligning with the slotted saddle of this tool. 5. Do not exceed the lifting capacity for any specific height of this tool. Exceeding the lifting capacity could cause personal injury and/or property damage. 6. This Scissor Jack is designed for short-term lifting of loads. Do not use for extended lifting of loads.

7. Use the Scissor Jack only on a flat, level, solid surface capable of supporting the weight of the Lift and the weight of the object being lifted. 8. Make sure any load being supported by this Scissor Jack is well balanced. Unbalanced loads may cause the lift to tip over, potentially causing serious personal injury and/or property damage. 9. Stay clear of the Scissor Jack. Never go under an object being supported by the Jack. Whenever possible, use jack stands (not included) to help support the weight of the vehicle being lifted. 10. This Scissor Jack is not designed to be used for aircraft purposes. 11. WARNING! Always turn off the vehicles engine before using the Scissor Jack. 12. Always monitor the vehicle being lifted so it does not rock back and forth. 13. WARNING! Avoid dangerous oncoming traffic. Make sure to move the vehicle to a flat, level, oil/grease free, ground surface as far away from the road or highway as possible prior to raising the vehicle with the Scissor Jack. 14. This Scissor Jack is designed to lift one wheel at a time for the purpose of emergency tire replacement. Once lifted, make sure to support the load immediately with appropriate vehicle support stands (not included). 15. Prior to lifting the vehicle, make sure to place the vehicles transmission in PARK (if automatic) or 1st GEAR (if manual). Then, set the emergency brake and block the tires opposite the tire being lifted. 16. Do not leave the Scissor Jack unattended when the tool is under a load. 17. Do not allow anyone in the vehicle while using the Scissor Jack. 18. Always keep hands, fingers, and feet away from the moving parts of the Scissor Jack when applying or releasing a load. 19. People with pacemakers should consult their physician(s) before using this product. Electromagnetic fields in close proximity to a heart pacemaker could cause interference or failure of the pacemaker. 20 The warnings and cautions discussed in this manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator.

3.6. To operate the Scissor Jack using the DC Plug

1. Set the Scissor Jack on the ground surface. Then plug the DC Plug into the vehicles cigarette lighter receptacle. NOTE: Depending on the vehicles make and model, you may need to turn the vehicles ignition switch to its ACCESSORY mode.

Figure (C):-operate scissor jack 2. Make sure to keep all wiring of the Scissor Jack away from its moving parts. 3. Press the DOWN Button on the Control Unit (32) to fully collapse the Scissor Jack 4. Once collapsed, slide the Scissor Jack under the vehicle, nearest the wheel that is to be removed. Make sure to chock the wheels opposite the wheel being removed. 5. IMPORTANT: The Scissor Jack is designed for use on vehicles with frame seams that are capable of sustaining rated capacity loads. Carefully position the Scissor Jack under a vehicle manufacturers recommended lift point. 6. Press the UP Button on the Control Unit (32) until the Saddle (1) of the Scissor Jack has nearly reached the frame seam. Make sure the seam will fit into the Saddle slot. NOTE: The Scissor Jack should be positioned at 90 degrees to the frame seam to ensure the Saddle slot and seam are in alignment. If not, remove and reposition the Scissor Jack before lifting the wheel.

Figure (D):- Use of scissor jack in car

7. Continue pressing the UP Button on the Control Unit until the wheel has been raised about one inch off the ground surface. Then, place a jack stand (not included) under the vehicle for added safety. 8. Remove the lug nuts from the vehicles wheel. Remove the wheel, and replace it with the spare wheel (not included). Then, tighten all lug nuts snugly onto the wheel. 9. Make sure the old wheel, tools, the jack stand, and all other objects are removed from under the vehicle. 10. Press the DOWN Button on the Control Unit (32) to lower the vehicles wheel. Continue pressing the DOWN Button until the Scissor Jack is completely collapsed. 11. Disconnect the DC Plug (33) from the vehicles cigarette lighter receptacle. 12.Make sure to store all parts of the Scissor Jack in its Carrying Case (35), and keep in a dry, clean, safe location out of reach of children and other unauthorized people.

CHAPTER-3 4. CONCLUSION
If you have the space and you do your own maintenance and repair, youre going to love having a table lift. The table lifts made by Handy, though a bit heavy and space hungry, are strong, well built, simple to use and should last a lifetime. They require only a periodic drop of oil and shot of grease as maintenance. Sure, there are some table lifts that are lighter and more compact, but when I work on my bike I want something thats solid, sturdy and versatile. And if I can demonstrate that it can be used for other purposes, its easier to sell to the Mrs. If the cost is a stumbling point, you could do like Ive done in the past and go in with some friends on the cost. Just be sure to lobby real hard to get it to reside in your garage.

5. SCOPES OF WORKS
1. The developed automatic car jack can only withstand below 1000kg of load (Kancil 682kg) II. The developed automatic car jack must be operated on a flat surface. III. The developed automatic car jack is only a prototype and not readily functioning as commercial product. IV. The design is based on current scissor jack in the market. V. The developed automatic car jack is only for normal person. VI. The developed automatic car jack can only work by using the internal car power (12V)

REFERNCES EJ212 Electric Jack 1 Ton Assembly & Operating Instructions; Buffalo Tools; 2009 http://www.electricscissor.com http://www.jack.com http://www.electricscissorjack.in http://www.autojack.org