PEDAL OPERATED FORK

LIFT

By,
Kunal Kotian (4PA07ME029)
Rao Sharana Kumar (4PA08ME402)
Srinidhi (4PA07ME057)
Abdul Rahiman (4PA08ME400)

Under the guidance of,

Mr. HEMANTH SUVARNA
Senior Professor
P.A college of Engineering, Mangalore
 CONTENTS
ABSTRACT

INTRODUCTION

FORK LIFT

SCOPE OF PRESENT WORK

SIDE VIEW OF PEDAL OPERATED FORK LIFT

DESCRIPTION OF PARTS

WORKING MECHANISM

DESIGN CALCULATIONS

DRAWINGS

COST ANALYSIS

FUTURE SCOPE

CONCLUSION

REFERENCE

MAKING OF PEDAL OPERATED FORK LIFT

 ABSTRACT
Many industries use fork lifts for lifting heavy goods etc. These are applicable for
large scale industries and highly automated industries.
Since the small scale industries requires repeated movement of load from one station
to another the use of these fork lift will not be economical. Hence we decided to
design a fork lift which helps small scale industries in transporting the load in easy and
cost efficient way.
The idea was to lift and shift the materials on shop floor where very low frequency of
shifting is required and the object being heavy enough for humans to shift the
materials. Where the lifting could be done by crank provided in a convenient
approachable place near the operator seat.
And once the load is lifted by the fork, the vehicle could be propelled with operator
itself by his pedaling effort just like a bicycle. Brakes are also operational by hand
near the seat so that its convenient enough. The vehicle could be steered easily without
any problem in the job floor as well meant for flat floor.
 INTRODUCTION

Material handling systems :

Material handling is defined as the movement of raw material, semi goods
through various stages of production and ware housing. It is concerned with
the movement, storage and control of materials in a production process.

Various material handling devices are

Conveyors

Cranes and hoists

Pipelines

Fork lifts etc.

This project is about providing small scale industry which are dominant in India with
custom designed fork lifts of variable capacity where the operating cost and
maintenance is just negligible hence economical and efficient. Since the whole
operating is purely manually or mechanically through cycle pedaling.
 FORK LIFT
Fork lifts are the material handling devices which are used to transport the
load from one station to another.
Forklifts are either powered by gasoline, propane, or electricity. Electric
forklifts rely on batteries to operate. Gasoline or propane forklifts are
sometimes stronger or faster than electric forklifts, but they are more difficult
to maintain, and fuel can be costly.
Rough terrain forklifts have the highest lifting capacity of all forklifts and
heavy duty tires like those found on trucks, making it possible to drive them on
uneven surfaces outdoors.

Several Types of fork lifts are:

1) Pallet jack
2) Rider motorized pallet truck
3) High lift pallet trucks
4) Front rider pallet trucks
5) Automated guided vehicle
Pallet jacks:
Pallet jacks are the most basic form of fork lift. Pallet jacks are intended to move heavy or
light pallets for relatively short distances. These do not have powered propulsion system
but are powered by the operator pushing and pulling the track. It consists of hydraulic
lifting mechanism controlled by the operator.

Rider motorized pallet trucks:

These are used when the transport distance is too great to make walkie practical, and are
ideal for frequent movement over extended distances. The rider truck travels at high
velocities presents an extreme hazard to the operator and any one near the lift is the major
problem.

High lift pallet trucks:

These are used as an alternative to forklifts, often performing same functions such as
moving loads on shelving.

Front rider pallet trucks

These are pallet trucks where operator stance is located between the front of the lift where
the forks are, and the rear of the lift where battery is stored. This provides some protection
to the operator. With a physical barrier in front and behind the operator, there is less injury
to the operator.
Automated guided vehicle (AGV):
It represents the future of materials handling technology. AGVs do not require operators
but travel along a route that is demarcated by frequency sensors, light beams or induction
tape. The removal of the operator from the fork lift saves the companys wages, and can
decrease the hazard level associated with the material handling responsibilities.

(Fig. AGV with load station)

 SCOPE OF PRESENT WORK
The main aim of our work is to help small scale industries.

It will lift the load of about 250kg . Fork is raised by turning a crank with your hand,
and you transport the goods by pedaling with your feet.

Quite a lot of forklifts are electric anyway though, but this one will moreover save
electricity along with fuel by eliminating their use. It does not require a battery too. So
it could be fairly green to start with.

But it is not applicable for hilly or sloppy areas where a large amount of power and
effort would be required which is not possible with just pedaling.

This unique design of the fork lift can be used on flat paths in industries/companies
where repeated loads are to be transported from one station to another thereby helping
in transferring the load easily which otherwise would be difficult through just manual
interference.
SIDE VIEW OF PEDAL OPERATED FORK lift
 DESCRIPTION OF PARTS
Body or main chasis:
The body is rectangular in section. It is made of mild steel. The front part is called as
channel where the frame travels. It is welded with stainless steel for easy movement of the
frame and to reduce friction.

Frame:
it is rectangular in section. It is made of mild steel. Its dimensions are 1500x900mm. The
frame reciprocates inside the channel and is welded with the fork which carries the load.

Fork:
the fork is made of mild steel and is welded to the channel .The dimensions of the fork are
600mm. The load to be lifted is placed on the fork and the frame along with the fork is
lifted using worm gear mechanism.

Worm and worm wheel:

this is used to lift the frame through chain. The material used is cast steel. The worm is
rotated by cranking the pulley.
The worm wheel is also called as worm gear. The material used is phosphor gear bronze.
The output from the gear is connected with chain and is fixed to the frame to lift the load.
Hand wheel:
The hand wheel consist of pulley and is welded to the rod. The diameter of the pulley is
200 mm. It is made of cast iron. The rotation of the pulley in turn rotates the worm.

Gear box:
The gear box consist of two shafts and idler shaft with five gears. The material used for
the gears is EN8. The gears are covered with the plates made of mild steel.

Pedal:
The input to the shaft which enables the gear to rotate inside the gear box is achieved
through pedaling. The pedals are made of steel. It is situated such that operator feels
comfortable to operate.

Sprockets:
There are two smaller diameter sprockets with diameter 65 mm which provides input to
the gear shaft and two larger diameter sprockets with diameter 160 mm is provided at the
output and is welded to the axle. The material used for the sprockets is alloy steel.

Tie rods:
The tie rods are made of mild steel. The dimensions is 400x20mm. It is connected to bell
crank which is linked to the stub axle.
Rear axle:
The rear axle is made of mild steel. The dimensions are 30mm . it is supported with
Plummer block and is connected to the wheels.

Stub axle:
The stub axle is made of mild steel. A bell crank lever with short arm diameter of 25mm
and length 90mm, a long arm taper section of length 180mm with bush diameter of
20mm.

Front and rear wheels:

The wheel hub is made of cast iron. The wheel is 250mm in diameter. The front and rear
wheels . all wheels are of same diameter.

Brake :
The brake consist of brake drum welded to the rear axle. A rod of suitable length is fixed
to the brake shoe. The brake handle is situated near to operators seat.
 WORKING MECHANISM
The fork lift which we have designed consists of three main mechanism :
Lifting mechanism using Worm gear

Steering mechanism

Pedaling mechanism for the movement of the vehicle

We have designed the system for 2500N and it can be used in small scale industries.

Lifting mechanism: The load will be lifted by using worm gear assembly chain block
system. It consist of worm, worm wheel, chain and a pulley for cranking. The rotation
of pulley enables the worm to rotate which in turn rotates the worm wheel. The chain
which is fixed to the output of gear helps in lifting the load placed in the fork of the
fork lift. The below figure shows lifting mechanism.
Steering mechanism:
It consists of bell crank lever, tie rods, steering rod consisting of eccentric pivot pin. One
end of both the tie rods are connected to the pivot pin and the other end of the tie rod is
connected to the longer arm of the bell crank lever on each side. The short arm holds the
front wheels. The pivot pin is connected to the steering rod. The wheels are steered by
rotating steering wheel.

Pedaling mechanism:
This mechanism comprises of gear box. The gear box contains two shafts (one for input
and other for output).It consist of 5 gears including an idler gear. Due to pedaling the input
shaft rotates, hence gear fixed to the shaft rotates which mates with the gear on the output
shaft. An idler gear is placed to move the vehicle in forward direction. When the lever
direction is changed the 3 gear assembly with idler gear is disengaged and the other two
gears are engaged which enables the vehicle to move in reverse direction.
 DESIGN CALCULATIONS
WORM GEAR
GEAR CALCULATIONS
GEAR 1 12 TEETH 24 DIA 2 no,s
GEAR 2 18 TEETH 36 DIA 1 no,s
GEAR 3 36 TEETH 72 DIA 1 no,s
GEAR 4 54 TEETH 108 DIA 1 no,s
Metric spur gears module 2 as per AISI 1146
12 to 29 tooth
AISI 1045 30 to 80 tooth
 DRAWINGS

MAIN FRAME:
SLIDER FRAME:
TIE ROD :
STUB AXLE:
STUB AXLE FRAME:
GEAR BOX
SPECIFICATION
Length of horizontal chassis frame = 1500mm
Length of vertical frame = 1800mm
Width of vehicle frame = 900mm
Travel length of frame = 1450mm
Chain block capacity = 5000N
Gear box two speed (front and reverse) 3:1 velocity ratio
Single operator
COST ANALYSIS
 FUTURE SCOPE
Hydraulics can be applied for lifting mechanism.

Pedaling mechanism can be replaced by using an engine.

The load capacity of the system can be increased by increasing the worm
dimensions.

Other steering mechanism such as rack and pinion etc can be introduced.
 CONCLUSION

The Pedal operated Fork lift which we have designed is limited to load capacity of 2500
N further improvements can be made in designing the chain blocks of higher dimension to
increase the lifting capacity .

Weight reduction of the structure is reduced to 30% of the whole structure.

The specialty of the existing design is that no need of providing the counter weight for
balancing since the load being lifted is transferred to the rare part of the structure through
the chain block being mounted on the ISMC which rests on the pipe frame.

Also further improvement in the movement of the vehicle can be obtained by replacing
the chain drive with differential system.
 REFERENCE

Design of machine elements by J.B.K.DAS.

Design data hand book by K.Mahadevan & K. Balaveera reddy.

Kulwiec,R.A,1985, Materials handling hand book ,wiley

interscience.
THE MAKING OF PEDAL OPERATED FORK
LIFT. . .
 assembled
AND FINALLY. . .
THANK YOU