UNIVERSITI KUALA LUMPUR

MALAYSIAN SPANISH INSTITUTE

(TWO LIFTING ARMS CAR JACK)

BY: MUHAMAD AFIZ BIN MOHAMMAD (54136209191) AIN NATASHA BINTI ZULKUFLI (54136209015) JACOB PEREIRA (54136209195)

Report Submitted to Fulfill the Partial Requirements for the Diploma of Engineering Technology in Mechanical Design and Development.

JULY 2011

DECLARATION

We hereby declare that this submission is our own work and that to the best of our knowledge and belief it contains neither material nor facts previously published or written by another person. Further it does not contain material or facts which to a substantial extent has been accepted for the award of any diploma of a university or any other institution of tertiary education except where an acknowledgement.

. (Muhamad Afiz bin Mohammad) 541362090 Date: / /2011

. (Ain Natasha binti Zulkufli) 54136209015 Date: / /2011

. (Jacob Pereira) 54136209195 Date: / /2011

APPROVAL

We have examined this report and verify that it meets the programmed and University requirements for the Diploma of Engineering Technology in Mechanical Design and Development.

. (Mr. Zainal Nazri bin Mohd Yusuf) Supervisor Date: / /2011

. (Mr. Abdul Rashid bin Abdul Rahman) Date: / /2011

ACKNOWLEDGEMENT

Two lifitng arms car jack has been developed successfully with a great contribution of many people within a period of six months. We would like to appreciate their guidance, encouragement and willingness since without their support the project would not have been a success. Firstly we would like to thank God who has been the highest helper for our project in many ways. Without God we cannot be completing this project successfully with the weather, time an etc. We would like to give our sincere gratitude to Mr. Zainal Nazri bin Mohd Yusuf, who was supervise our project and helping us in many ways, sharing some information and knowledge, giving us some idea and also help us in solving problems to make sure our project succeed. We are also grateful to Mr. Abdul Rasid bin Abdul Rahman who has been behind us guiding all the projects from and giving us very valuable feedback Both our supervisor who was a really helpful people who guided us in fabricating so many parts for our project. We are also grateful to the whole technician of the Workshop Section including- Mr. Mohd Faizal bin Osman, Mr. Azren bin Ahmad, Mr. Asrulwadi bin Ismail, Mr. Mohd Shukor bin Salleh and others for their inspiring technician, give feedbacks and helping us on how to using workshop equipments. We would also thank our parents and family member for giving us the financial support and the courage to complete this final year project. We would like to thank them because of the great advises and support that they gave us from the starting till the end of this project.

CONTENTS
DECLARATION APPROVAL ACKNOWLEDGEMENT CONTENTS LIST OF TABLES LIST OF FIGURES CHAPTER 1 INTRODUCTION 1.1 Introduction 1.2 Project Motivation 1.3 Background 1.4 Problem Statement 1.5 Objectives 1.6 Scope and Limitation CHAPTER 2 LITERATURE REVIEW 2.1 Introduction 2.2 Terminology 2.2.1 Design 2.2.2 Jack CHAPTER 3 DESIGN DEVELOPMENT 3.1 Project Development Stages 3.2 Project Fabrication Stages 3.2.1 Project Planning and Scheduling 3.2.2 Gantt Chart 3.3 Concept of Car Jack 3.3.1 How does a two lifitng arms car jack work? 3.4 Fabrication and Development 3.4.1 Confirm Design 3.4.2 Build Mock-Up CHAPTER 4 METHODOLOGY 4.1 Parts Development 4.1.1 Outer Body 4.1.2 Gears and Couplings Mechanism 4.1.3 Lifting Arm 4.1.4 Lifting Base 4.1.5 Rollers Part 4.1.6 Finishing Process 2 3 4 5 7 8 9 10 16 19 21 24 25 26 27 32 32 32 36 37 39 40 43 44 44 55 55 55 56 57 57 62 67 70 80 81

CHAPTER 5 RESULT AND DISCUSSION 5.1 Testing the Product 5.2 Problems Facing and Solutions 5.3 Result CHAPTER 6 CONCLUSION AND DISCUSSION 6.1 Recommendation 6.2 Conclusion REFERENCES APPENCISES

82 83 84 85 87 88 89 90 91

LIST OF TABLES
Table Table Table Table Table Table Table 1 2 3 4 5 6 7 Pahl and Beitz Model of Design Process Stages of project development Stages of project fabrication 1 Structure of product development Gantt chart CNC Milling Programming EDM Programming

LIST OF FIGURE
Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Screw lifting jack Long floor jack Pneumatic jack Pneumatic jack House jack Strand jack Current jack in market Tire change fail Mechanic servicing car Electric car jack Preparing tools Proper located of car jack Proper position point of car jack Place jack stands Lower the car jack to the stand Stop lowering the jack Spur gear and rack gear Marking plate Hand sawing machine DANOBAT band sawing machine Cutting plate process Position of hole in plate Surface grinding control Facing process Spur gear Position of spur gear and rack gear Gear fix into the lifting arm Assembling process of arm Dimension of lifting arm Drilling hole on arm plate Grinding process Cover of arm set Lifting base 1 & 2 Process of shaping lifting base plate CNC Milling Lifting base 1 Bending process Lifting base 2 Cutting process of lifting base using EDM Bending process Front roller 10 12 12 13 13 14 14 15 16 20 25 26 26 27 27 28 41 42 42 43 43 44 45 47 50 50 51 51 52 53 53 54 55 57 57 57 57 60 62 63 64

Figure Figure Figure Figure

42 43 44 45

Back roller Assembled of part project Result of project Result of project

64 65 68 69

Chapter 1: INTRODUCTION
1.1 INTRODUCTION

This report describes about the types of jacks that are in the market now days. It is a device used in workshops to lift heavy loads or apply great forces to carry a vehicle. There are many types or jacks in the market. Firstly, the mechanical 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 by manual force alone. 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, 2 tons, and 3 tons). The jack shown below is made for a modern vehicle and the notch fits into a point on the body. Earlier versions have a platform to lift on the vehicles' frame or axle. This is a common car jack found in car when the car is purchased by someone from the car dealers.

Figure 1 Screw Lifting Jack

10

Secondly, the hydraulic jacks are typically used for shop work, rather than as an emergency jack to be carried with the vehicle. Use of jacks not designed for a specific vehicle requires more than the usual care in selecting ground conditions, the jacking point on the vehicle, and to ensure stability when the jack is extended. Hydraulic jacks are often used to lift elevators in low and medium rise buildings.

A hydraulic jack uses a fluid, which is incompressible, that is forced into a cylinder by a pump plunger. Oil is used since it is self lubricating and stable. When the plunger pulls back, it draws oil out of the reservoir through a suction check valve into the pump chamber. When the plunger moves forward, it pushes the oil through a discharge check valve into the cylinder. The suction valve ball is within the chamber and opens with each draw of the plunger. The discharge valve ball is outside the chamber and opens when the oil is pushed into the cylinder. At this point the suction ball within the chamber is forced shut and oil pressure builds in the cylinder.

In a bottle jack the piston is vertical and directly supports a bearing pad that contacts the object being lifted. With a single action piston the lift is somewhat less than twice the collapsed height of the jack, making it suitable only for vehicles with a relatively high clearance. For lifting structures such as houses the hydraulic interconnection of multiple vertical jacks through valves enables the even distribution of forces while enabling close control of the lift.

In a floor jack a horizontal piston pushes on the short end of a bell crank, with the long arm providing the vertical motion to a lifting pad, kept horizontal with a horizontal linkage. Floor jacks usually include castors and wheels, allowing compensation for the arc taken by the lifting pad. This mechanism provides a low profile when collapsed, for easy movement underneath the vehicle, while allowing considerable extension.

11

Figure 2 Long Floor Jack

Figure 3 Pneumatic Jack

The third type of jack is the pneumatic jack. It is a hydraulic jack that is actuated by compressed air - for example, air from a compressor - instead of human work. This eliminates the need for the user to actuate the hydraulic mechanism, saving effort and potentially increasing speed. Sometimes, such jacks are also able to be operated by the normal hydraulic actuation method, thereby retaining functionality, even if a source of compressed air is not available.

12

Figure 4 Pneumatic Jack

Next, a house jack, also called a screw jack is a mechanical device primarily used to lift houses from their foundation. A series of jacks are used and then wood cribbing temporarily supports the structure. This process is repeated until the desired height is reached. The house jack can be used for jacking carrying beams that have settled or for installing new structural beams. On the top of the jack is a cast iron circular pad that the 4" 4" post is resting on. This pad moves independently of the house jack so that it does not turn as the acme-threaded rod is turned up with a metal rod. This piece tilts very slightly but not enough to render the post dangerously out of plumb.

Figure 5 House Jack

13

Lastly, is the strand jack. It is a specialized hydraulic jack that grips steel cables; often used in concert, strand jacks can lift hundreds of tons and are used in engineering and construction.

Figure 6 Strand Jack

Figure 7 Current Jack in market

Well, this is the types of jacks that are in the market at this moment. In conclusion, we can say that jacks are meant for carrying heavy loads.

14

1.2 PROJECT MOTIVATION

An automotive jack is a device used to lift 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 especially in automotive industry and workshop to helping technician and mechanic repairing their customers vehicle with more safety precaution and quickly. 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.

Figure 8 Tire change fail

15

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.

Figure 9 Machanic servicing car

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. Thanks to ALI's cooperative venture with the American National Standards Institute, all jacks and lifts must meet a set number of performance standards in order to be ALI/ANSI certified. 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.

16

1.3 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. Furthermore, available jacks are typically large, heavy and also difficult to store, 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. In light of such inherent disadvantages, some researcher including students tries to generate a new idea and their attitude on how to develop an Two lifitng arms car jack for our future. However, due to their size and high costs of purchasing and maintaining this car jack, such Two lifitng arms car jacks are not available to the average car owner. Engineering is about making things simpler or improving and effective. So we try to develop a car jack in the small scope as an experiment so that it could be a signal to the world on our effort to solving these problems nowadays. 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 it is fails to work after lifting 250 kilograms and may physically break when it has a weight close to its 1000 kilograms capacity.

17

Whilst no injuries have been reported to date, it was rising 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. The purpose of this project is to develop a car jack which is easy to be operated, safe and able lift and lowering the car without involving much physical effort. It is almost fulfill automotive industry requirement especially in workshop to help mechanics and technician make their works easily without any problems.

18

1.4 PROBLEM STATEMENT

According to this necessity, we have find out the entire users problem (especially drivers and mechanics) and try to solve it also developed this product of car jack that existing on the market become more better based on technology provided nowadays. 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. Besides, present car jack just have only one lifting arm to support the load. With this new design, we try to minimize the size of car jack with maximum lifting capacity so it can folded up in the vehicle and safe some space, lighter the weight of material used and also to ensure the stability when the jack is extended so anyone can bring it easily. Furthermore, available jacks are typically large, heavy and also difficult to store, carry or move into the proper position under an automobile. Suppose car jacks must be easy to use for whoever person and easy to control the movements of the car jack. Lastly, normally all car jacks cannot be change or modified if it is spoil. If it spoils, the only way is to get a new one. So the cost of buying it is expensive. The price depends on the load that the jack can be carried.

19

From the problems and our effort to develop the car jack to be as Two lifitng arms car jack, weve list the problem solution as shown below:i. Weve developed this car jack with two lifting base that can stand with any weight of vehicle and increase the stability and capability than one lifting base as usual. This allow technician and users do their work safely. ii. First of all, weve planned to use a motor for supply power to the car jack. But it is not stronger at all especially when there is sudden black out and we need to make sure the motor is function every time before it can be use.

Figure 10 Electric car jack

We use hydraulic system to the jack which used a fluid, which is incompressible, that is forced into a cylinder by a pump plunger. Oil is used since it is self lubricating and stable. iii. This Two lifitng arms car jack is jacking from the side, so the mechanic has more space at the front side to do their works.

20

iv.

When this product is not been used, it can folded up and the roller made inside the base can move freely.

v.

The lifting base of Two lifitng arms car jack can be extended to the size of vehicle (width) and it was make by rubber padded lifting platform prevents scratching and protects the vehicle.

vi.

We used mild steel that is cheap, high stiffness and strong. Most of mild steels are easy to machine and weld.

vii.

We also use and fabricate parts that can be dismantled. This is for maintenance purpose of the jack.

21

1.5 OBJECTIVES

In order to fulfill the needs of present car jack, some improvement must be made base on the problem statement:i. To design a car jack that is safe, reliable and able to raise and lower the height level ii. To design and fabricate the car jack which has develop with more multifunctionality car jack.

iii.

To design a car jack with easy maintenance and less cost

22

1.6 SCOPE AND LIMITATION

i. ii. iii. iv. v. vi.

A simple car jack that used for workshop and automotive industry. These car jacks are prohibited from using for lorry, bus and any heavy vehicle. The developed car jack can only withstand below 2 ton of load. The developed car jack must be operated on a flat surface. The developed car jack is only a prototype and not readily functioning as commercial product. The design is based on current lifting base in the market with some comparison and adjustment.

23

Chapter 2: LITERATURE REVIEW

2.1 INTRODUCTION

The main purpose of this literature review is to get information about the project from reference books, magazine, journals, technical papers and web sites. In this chapter, the discussion will be made base on all the resources. First of all, the concept of our product was found by doing some research on how the car jack lifting cars (vehicle) by us at Kulim, Kedah and surfing some videos car jack lifting cars (vehicles) by internet. Below is the manual way of lifting cars (vehicle) by a car jack. This how-to article aims to help illustrate proper vehicle jacking procedures. As a disclaimer, we always recommend that you read your vehicle's manual (or better yet - the factory workshop manual) before attempting any service items. In this how to, you will be required to know and identify the factory approved "jack points". Typically, these points can be found under "Emergency" in the vehicle operator's manual. Because of the dangers of having a 1000+ kg vehicle looming over you as you work, we will accept absolutely no responsibility for any accidents that may occur while you service your vehicle (*one of the reason for us developing the car jack with more safety precaution). Safety is everybody's responsibility- the following article will attempt to reinforce this concept.

24

Before you buy jack-stands, and a floor jack be sure that each component is strong enough to support at least half of the vehicle's "curb weight".

Figure 11 preparing tools

i.

As safety is a major focal point of this write up, all steps will have some proximity to safe practices - the first step is a subtle example. Before you consider jacking up a vehicle, find as flat work area as possible.

ii.

Move the vehicle into position. You should place cinder blocks, 4 x 4 blocks, or similar large wedges in front and behind the wheels which will remain on the ground during the initial jacking process.

iii.

Be sure to chock the front wheels. If the vehicle is front-wheel drive, put the vehicle into reverse gear. State the floor jack in the approved factory location. Be sure to place the jack in an accessible location, free of interference with any vehicle chassis parts.

25

Figure 12 Proper located of car jack

iv.

Begin jacking the vehicle up using the floor jack. Be very cautious whilst raising the vehicle. This is where most accidents occur.

Figure 13 proper position point of jack

v.

Once the vehicle is raised sufficiently, place the jack-stands under the factory approved jacking points.

26

Figure 14 Place jack-stands

vi.

Be sure to always use a minimum of two jack-stands when raising the front or rear of a vehicle.

Figure 15 Lower the car to the jack stands

vii.

Then, you may slowly lower the vehicle onto the jack-stands. If you run into problems, jack the vehicle back up and re-position or re-plan your jacking sequence.

27

Figure 16 Stop lowering the jack

viii.

Stop lowering the jack and raise it back up one "notch. Give the vehicle a slight nudge to ensure that the forces you will exert during your mechanical procedures will not cause the vehicle to become unstable and fall off the jackstands thus killing someone below. Once you are satisfied that you have done to make the worksite as safe as possible, you have completed that jacking up of your vehicle.

28

2.2 TERMINOLOGY

In this section, all the terminology on this project is presented. 2.2.1 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). 2.2.2 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.

29

These terms are defined as follows: i. ii. Functional: The product must perform to fill its intended need and customer expectation. 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. v. Competitive: The product is a contender in its market. Usable: The product is user friendly accommodating to human size, strength. Posture, reach, force, power and control. The developed car jack is only a prototype and not readily functioning as commercial product. vi. Manufacturing: 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 starts by identifying exactly how to recognize or get a satisfactory alternative, and how to distinguish between two satisfactory alternatives in order to get a perfect solution. From this, optimization strategies can be formed or selected.

30

Then the following tasks unfold: i. ii. iii. iv. v. 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.

31

Table 1 Pahl and Beitz Model of Design Process

32

Chapter 3: DESIGN DEVELOPMENT

3.1 PROJECT DEVELOPMENT STAGES

Here, we have list the combination method used in order to accomplish our project. We go through this procedure around four months to make and gather some information, drawing process, and concepts of the project. i. ii. iii. iv. v. Doing some research to the already existing car jack Doing survey on some workshops about car jack Research done to improve the weakness of car jack Using common tool or equipments any mechanical works. Getting information for supervisors about the project development.

33

Table 2 Stages of project development

34

3.2 PROJECT FABRICATION STAGES

Table 3 Stages of project fabrication 2

35

3.2.1

Project Planning and Scheduling

This project is concern to mechanical and development process, which we create a model of a new car jack with some improvement and development. Furthermore, the project coalesce with mechanical engineering, technical drawing, and metrology needs. Formerly, before designing the products and process plan take in action, some study and research is being approach to advisors and all group members. Moreover, this is to ensure that we could carry out the task given in the specific time and to achieve the objective of the project. Several actions that have been done before fabricate the product are:i. Brainstorming Brainstorming is a process for developing creative solutions to problems. It works by focusing on a problem, and then deliberately coming up with as many solutions as possible and by pushing the ideas as far as possible. One of the reasons it is so effective is that the barnstormers not only come up with new ideas in a session, but also spark off from associations with other peoples ideas by developing and refining them.

ii.

Analysis Since our project is based on automotive industry requirements, we gathered all the information from supervisor, lecturers, and technicians and also access the internet. We had some survey with some technician to know some of their problems with the current jack that might help us in this project.

36

The existing product in the international market is almost not suitable for the automotive industry because of the lacking safety and less functionality. Therefore our group has decided to fabricate the same car jack with some improvement and development that everyone can use it.

iii.

Product development Our product development is based on 3 stages. These three stages consists on mechanical section. From the mechanical section stages including drawing and design,, build the structure and lastly testing the product.

Table 4 : Structure of product development

Through this stage, there were confirm designed for the product which has been agreed by the entire groups members and also our supervisor and co supervisor.

37

iv.

Flow chart Flow chart is one of the 7 Basic Quality Control Tools. It is a diagram that visually shows how resources move through various operation of the production system. It shows the entire stage of the production where the operation must be carried out following the sequences. The flow chart makes it easier to visualize the production operation. If any problems occur during stage, the process needs to be returned back to their earlier stage.

38

3.2.2

Gantt chart

Gantt chart represents graphically on a time scale as to when certain operation would be performed. It is also useful in recording the progress of the schedule. The activities are listed vertically and the time period is indicating horizontally. It is also known as the bar chart.

Table 5 TASK DESCRIPTION Detail drawing Confirm design Buy material Check compatibility Part fabrication Assemble Project testing Finding problems Prototype Final presentation Submission report / / / / / 1 / 2 / / / / / / / / / / / / / / / / / / / / / / / / / / 3 4 5 6 7 8 9 10 11 12 13 14

39

3.3

CONCEPT OF CAR JACK

3.3.1 i.

How does a two lifitng arms car jack work? The Mechanism A car jack is a mechanical device that allows drivers and mechanics to get underneath a car, usually to change a tire, oil or some body part like brakes or struts. When most people hear the term floor jack, they think of the automobile floor jack. It uses a pump arm, hydraulics to lift vehicles to gain access to the undercarriage. The jack makes easy work out of changing a tire or doing a brake job. This is not to be confused with a hydraulic lift used in auto repair shops. A floor jack needs solid ground or concrete to give it a good base that doesn't shift. There is a lip that can be attached to the automobile itself and is gently raised by pumping the arm and hydraulic system .The jacks are rated by the amount of weight they can lift safely. A 2 jack is what you would normally carry around in your car to change a tire or carry the front part of the car to perform repair in front of the car (the place the engine is).

40

ii.

Get the car jack to lift up the car. The Two lifitng arms car jack uses the same concept as the floor jack used in workshop. Where by theres a holder to jack the jack up. By pressing the holder up and down, the arm will raise up because of the extension on the piston from the hydraulic system which pushes the rack gear to left arm of the jack. And the right arm has a gear that goes on the rack gear, so when the rack gear moves forward the gear on the arm moves to lift the arm.

Figure 17 Spur gear and rack gear

iii.

Bringing the Car Down There is a lot of weight supported by the jack. Make sure to follow all the safety suggestions, and that the jack is placed on a flat, concrete surface and no one is sitting in the car. The car descends by reversing the process: turn the screw counterclockwise.

41

Chapter 4: METHODOLOGY
4.1 4.1.1 OUTER BODY PARTS DEVELOPMENT

Step 1: Cut and shape the outer body i. First, we measure and marking the steel plate using scriber based on the dimension in drawing.

Figure 18 Marking plate

ii.

Then, we cut the steel plate using hand sawing machine in the work shop.

Figure 19 Hand sawing machine

42

iii.

After that, we use DANOBAT band sawing machines to cut the angle of 30 at the end of the steel plate.

Figure 20 DANOBAT band sawing machine

iv.

Because design of the steel plate is quiet difficult to fabricate using the machines; we had to go to the old-school method that is by using a handsaw and files. We request G-Clamp and Hand Saw at the FYP Cabins technician to cut it by our effort.

Figure 21 Cutting plate process

v. vi.

We use flat file and hand grinding to make the finishing. Finally, weve finish to cut, measure and shape the outer body for Two lifitng arms car jack.

43

Step 2: Drilling hole i. First, we measure and marking the steel plate using scriber based on the drawing, dimension and mock-up.

Figure 22 Position of hole on plate

ii.

Using nail punch that struck by hammer, we marking the position that we want to drill. (7 holes; two for shaft roller, two for pivot points of arm, one for gear shaft, one for roller and the rest for hydraulic jack)

44

Step 3: Surface Grinding

Figure 23 Surface Grinding Control

i.

Using Surface Grinding Machine, we remove the rust and make the plate thinner than the original width as 6 mm tp 4 mm.

ii.

Procedure for Use :i. The first step in using the surface grinder is to make sure that the material we wish to shape can be used in the grinder. Soft materials such as aluminum or brass will clop up the abrasive wheel and stop it from performing effectively, and it will then have to be cleaned. This process is explained by the technician. The maximum size of a material that the grinder can machine is 18 long by 8 wide by 6 high. ii. The next step is to make sure the material is secured. This is done by use of a vice, and then by engaging the magnetic clamp. Once the material is secure, it must be manually positioned under the abrasive wheel. This is done by turning the longitude and latitude wheels located on the front of

45

the grinder. The abrasive wheel itself can be moved slightly to get the material in the perfect position. iii. Then the machine may be started. It should reach maximum speed

before you try to use it for the safety reasons mentioned before. If the wheel is working properly, then the hydraulic table can be activated which will then begin to oscillate under the wheel, cross-feeding towards or away from you as required. The automated speed and direction of the tables oscillations can be set as required or manually used when very precise work needs to be done. iv. If needed, a lubricant may be used to speed up or facilitate the grinding process. For this machine Cut well 45 is used. It is delivered via a tube beside the wheel, and falls onto the material being used. The excess fluid is then drained into the reservoir.

46

4.1.2

GEARS AND COUPLINGS MECHANISM

1st and 2nd coupling The 1st coupling is used to join the piston of the hydraulic and the rack gear. The part is done by lathe machining. The 2nd coupling is used to join the rack gear with the shaft that is linked to the arm of the jack.

Figure 24 Facing process

47

Procedure 1. Clamp the work piece onto the Chuck of the lathe machine. 2. Check the dimension of the work piece using a vernier caliper to avoid mistake. (Diameter of the work piece 34mm) 3. Set the cutting tool, and then drill a hole using the center drill. 4. Push the life center to the work piece. It to avoid the work piece from coming out of the jaws of the Chuck. 5. On the machine, and face the work piece. Then perform turning process. 6. Turn the work piece till the diameter is 30mm and the length of 50mm. 7. Drill a hole of 10mm on the work piece. 8. Then change the tool to the grooving tool. 9. Perform internal grooving for another 10mm. 10. Off the machine and remove the work piece. 11. Performed this procedure for the second coupling.

48

Then Conventional milling is used to make the hole for the coupling so that the rack gear can be fitted into the coupling. We had to use Conventional milling because the Lathe machine cannot perform the cutting of a square shape. Procedure 1. Mark the center of other side of the work piece. 2. Clamp the work piece (standing position) using the clamps on the conventional milling machine. 3. Clamp a drill bit of 10mm and drill the center. On the machine. 4. Remove the Arbor for the machine. 5. Clamp the end mill of the diameter 8mm onto the arbor, and clamp it to the machine. 6. Start making a Square by making using the end mill. The width of 20mm and length of 20mm on the work piece with the depth of 20mm. 7. Performed this to both of the work piece. 8. Stop the machine, and change the Work piece in sleeping positon. 9. Then change the tool, from the end mill to the drill bit to drill a hole. This hole is for the M4 screw that is used to clamp the gear with the coupling. 10. Then stop the machine, and remove the work piece. 11. Take the 1st coupling and lay it on the sleeping position. The part that is lathe. 12. Take a drill bit of size diameter 20mm and drill the side. This is to hole the hydraulic piston and the coupling. 13. Off the machine and remove the work piece. 14. Clean the machine.

49

Gears The gears in this project, we had to purchase it from a gear shop in Seberang Perai. This is because we do not have the knowledge and the tools to make a gear in our university. Two solid spur gears and a rack gear.

Figure 25 Spur gear

Figure 26 Position of spur ger and rack gear

50

Figure 27 Gear fix into the lifting arm

Using conventional milling, we make two holes diameter 8.3 mm to insert two shafts into it so the first gear that attached to the arm will be in fix condition.

Figure 28 Assembling process of arm

51

4.1.3

LIFTING ARM

Step 1: Cut and shape the arms i. First, we measure and marking the steel plate using scriber based on the dimension in drawing.

Figure 29 Dimension of lifting arm

ii.

Then, we cut the steel plate using shearing machine that is in work shop nearby the basic fitting workshop.

52

Step 2: Drilling hole and surface grinding i. After that, we just follow the same step of making the outer body with drilling hole using Conventional Milling and remove rust using Surface Grinding Machine at the four pieces of our lifting arms.

Figure 30 Drillipng process

Figure 31 Grinding process

53

Step 3: Welding the top cover of the lifting arm i. Welding is a fabrication that joints materials by causing coalescence. This is often done by melting the work pieces and adding a filler material to form a pool of molten material (weld pool) that cools to become a strong joint.

Figure 32 Cover of arm set

54

4.1.4

LIFTING BASE

Figure 33 Lifting base 1 and 2

1st lifting base Step 1: Measure and marking the steel plate i. First, we measure and marking the steel plate using scriber based on the dimension in drawing. Step 2: Computer Numerical Control Milling (CNC Milling) i. Using Computer Numerical Control Milling (CNC Milling), we keep in the programming to cut the steel plate.

55

Table 6 : CNC Milling Programming

N010 N020 N030 N040 N050 N060 N070 NO80 N090 N100 N120 N130 N140 N150 N160 N170 N180 N190 N200 N210 N220

G54 T1D1 M06 G00 M08 G90 G41 G00 G01 G01 G02 G01 G02 G01 G02 G03 G01 G03 G02 M09 M30 X-10 X0 X0 X50 X183.6 X233.6 X233.6 X216.1 X166.1 X67.5 X17.5 X0 Y-10 Y99.6 Y114.6 Y114.6 Y114.6 Y114.6 Y99.6 Y73 Y13 Y13 Y73 Y99.6 R105 R45 R45 R105 R25 R25 Z10 G94 G97 G17 F400 S1000 M03 X0 Y0 Z10

56

Figure 34 Process of shaping lifting base plate

Figure 35 CNC Milling machine

Step 3: Conventional Milling i. After that, we make two slots on the work piece which this slot functioning as a sliding slot to the lifting base 2. We use conventional lathe to done this task.

Figure 36 Lifting base 1

57

Step 4: Drilling porcess i. Next, we drill four hole with diameter 8.3 mm.

Figure 37 Lifting base 1

58

Step 5: Bending process

Figure 38 Bending process

In press brake forming, a work piece is positioned over the die block and the die block presses the sheet to form a shape. Usually bending has to overcome both tensile stresses as well as compressive stresses. When bending is done, the residual stresses cause the material to spring back towards its original position, so the sheet must be over-bent to achieve the proper bend angle. The amount of spring back is dependent on the material, and the type of forming. When sheet metal is bent, it stretches in length.

59

2nd lifting base

Figure 39 Lifting base 2

Step 1: Measure and marking the steel plate i. First, we measure and marking the steel plate using scriber based on the dimension in drawing. Step 2: Electrical Discharge Machine i. Using Electrical Discharge Machine, we keep in the programming to cut the steel plate.

60

Table 7 : EDM Programming

N010 N020 N030 N040 N050 N060 N070 NO80 N090 N100 N110 N120 N130 N140 N150 N160 N170 N180

G54 T1D1 M06 G90 G41 G01 G01 G01 G03 G01 G03 G01 G03 G01 G03 G01 G01 M30 X-55 X-11 X-11 X-42 X-102 X-133 X-133 X-102 X-42 X-11 X-11 X-5.5 Y-53.8 Y-53.8 Y-73.6 Y-104.6 I-31 Y-104.6 Y-73.6 Y-34 Y-3 Y-3 Y-34 Y-53.8 Y-53.8 I0 J-31 I31 J0 I0 J31 J0 G94 G97 G17 F400 S1000 M03

61

Figure 40 Cutting process of EDM

62

Step 3: Drilling process i. After that, we just follow the same step of making the first lifting base with drilling hole using drill press. (our steel plate size and width are smaller, so that we can use this machine than CNC or conventional milling machine)

Step 4: Bending process

Figure 41 Bending process

In press brake forming, a work piece is positioned over the die block and the die block presses the sheet to form a shape. Usually bending has to overcome both tensile stresses as well as compressive stresses. When bending is done, the residual stresses cause the material to spring back towards its original position, so the sheet must be over-bent to achieve the proper bend angle. The amount of spring back is dependent on the material, and the type of forming. When sheet metal is bent, it stretches in length.

63

4.1.5

ROLLERS PART

Step 1: Front rollers assembled i. We attach the shaft and roller into the hole of the body.

Figure 42 Front roller

ii.

We put washer and nut at the end of the shaft.

Step 2: Behind rollers assembled i. ii. First, welding the cover plate of the behind rollers to the body. We need to make sure that the parts is stable and strong to lift heavy load. Drill hole on the top of the cover plate so we can put bolt, washer and nut through it.

Figure 43 Back roller

64

4.1.6

FINISHING PROCESS

After all the tasks have done the fabricating process, we assembled all the parts to the as a one product.

Figure 44 Assembled of part

65

Chapter 5: RESULT AND DISCUSSION

5.1 TESTING THE PRODUCT
Finally, after the product had finished, we have try to test it whether it is functional or not. Besides, we have also recorded it into the video to show the movement of mechanism. Based on the testing that we make on the product, the mechanism is completely functioning including:-

i. ii. iii. iv. v.

Movement of rack gear and spur gear Movement of hydraulic jack and shaft to the end that attached with coupling parts Movement of sliding lifting base one and two Movement of the lifting base when we lift the jack Movement of the roller at the bottom of the car jack

66

5.2 PROBLEMS FACING AND SOLUTION

i. At first, the lifting arm is not in stable condition especially when lifting load so we welding the top cover onto it. ii. We planned to attach the gear to the arm into the fix condition by welding, but after a few discussions, we discuss to drill two hole on the gear. iii. First design, rack gear at the bottom of the jack is not support by anything. And we found a problem that the rack gear will bending when lifting the load. So, we put a shaft at the bottom of the body to support the rack gear.

67

5.3 RESULT
The Fabrication of Two lifitng arms car jack is successfully complete by our group according to the planned. All of us were really excited in completing all the tasks to complete this project as well. All of the figure below shown about our parts and product :-

68

Figure 45 Result of project

69

Chapter 6: CONCLUSION AND DISCUSSION

6.1 RECOMMENDATION
There are some parts of our product that can be upgrade in the future such as: i. The mechanism itself For example, the gear can be changed in size to the smaller one to decrease the weight of the two lifting car jack. ii. The hydraulic system also can be changed by using the power motor with details safety and precaution to lifting the car jack. iii. The two pairs of roller at the bottom of car jack body can be changed to the 360 movement so the car jack can move freely. iv. The sliding of lifting car jack For example, current product using a roller can be changed to the bearing components so the sliding lifting base can be more smoothly.

70

6.2 CONCLUSION
Finally, we have managed to complete our final year project and successfully achieved the objectives. Furthermore, the Two lifitng arms car jack had accomplished the objectives such as: i. To design a car jack that is safe, reliable and able to raise and lower the height level ii. To design and fabricate the car jack which has develop with more multifunctionality car jack.

iii.

To design a car jack with easy maintenance and less cost

Besides, during developing project, all of us had learned a lot of a new knowledge such as fundamentals of the operation and about the time management that is very important to make sure the project is finished within the time given. Moreover, we also study about the system, design of the parts, material, and safety precautions during the project method.

In addition, hopefully our product will help our automotive industry especially to the users, technicians and workers, in improving the current car jack so we can avoid any accidents that may be occur when using the car jack.

Lastly, suspiciously we can practice and applied all of the knowledges and experience that we have learned from the first semester until the last semester and also learned from our final year project.

71

REFERENCES
i. ii. iii. iv. R.C. Hibbeler, (2005), Mechanics of Materials, Prentice Hall Pearson Education South Asia Pte Ltd Ferdinand P. Bee, E. Russell Johnston,Jr, Elliot R. Eisenberg (2004), Vector Mechanics for Engineers,Tata McGraw-Hill Robert L. Mott (2006), Machine Elements in Mechanical Design, Prentice Hall Pearson Education South Asia Pte Ltd Alawiah Ariffin (2009), Complete Reference Matriculation Physics 1,Oriental Academic Publication

Internet Resources http://www.efunda.com/processes/metal_processing/bending.cfm http://www.botlanta.org/converters/dale-calc/gear.html http://www.roymech.co.uk/Useful_Tables/Drive/Gears.html http://en.wikipedia.org/wiki/Jack_(device) http://en.wikipedia.org/wiki/Lathe http://www2.northerntool.com/auto-jacks.htm http://en.wikipedia.org/wiki/Milling_machine http://www.fixya.com/tags/car_jack http://www.workshopmachinery.com/

72

APPENDICES

73