ABSTRACT

A Rack and Pinion Lift is composed of two gears and a Rack and Pinion

arrangement. The flat helical gear is the rack and the round helical gear is the

pinion. The rack has teeth cut into it and they mesh the teeth of the pinion gear.

Also a spur gear is connected to the shaft of the pinion. And this gear is connected

to another gear by using a chain drive. One of the spur gear is connected to the

shaft of the torque and transfer power by using a chair. The motor is running by use

of 12 v battery. A rack and pinion is used to convert between rotary and linear

motion. This rack and pinion lift is commonly used in many industrial applications.

A rack and pinion lift consists of a rack and a pinion engaging also transfer motion

to or from a special kind of spur gear called a rack consisting of series of teeth in a

straight line on a flat surface. The invention relates to rack and pinion lifts, which

include a lift car which is driven via toothed wheels by means of an electromotor

along a rack carried by a lift mast, said car containing a control and maneuver unit

for the electric motor with a control and maneuver button set including floor call

buttons, landing based call button units being connected to said control and

maneuver unit via a ground level unit from which also a power cable leads to the

lift car. In association with the lift car a sensor device is arranged to indicate

passage of teeth of the rack or the toothed wheel and produce corresponding

position impulses, which represent the position of the lift A micro computer system

is connected for receiving the position impulses and for collecting and storing call
impulses from the call units and destination impulses from the button set of the

control and maneuver unit and based upon the position of the lift car ordering

travel direction, retardation and stop of the lift car. Said micro computer system

includes on the one hand a programmable micro computer unit in the lift car with a

register for position impulse numbers corresponding to the positions of the

landings, inputs for landings and outputs for controlling operation of the electric

motor, on the other hand a micro computer unit scanning the call button units with

respect to their state and associated with the ground level unit and communicating

with the programmable micro computer unit in the lift.

CHAPTER-1
1. INTRODUCTION
A Rack and pinion gear system is composed of two system of cars to convert

the rotary motion to the steering gears. The normal helical gear is the pinion

gear and the wheel to the side to side motion in the wheel . straight helical

gear is the rack. The rack has teeth cut into A rack and pinion consists of a

pinion engaging and it and they mesh the teeth of the pinion gear. Rack and

transferring motion to or from a special kind of spur gear, pinion gear

provides a greater feedback and steering called a rack, consisting of a series

of teeth in a straight sensation A well designed mechanism such as the line

on a flat surface. The rack and pinion changes linear rack and pinion gear

save effort and time. The rack and motion into rotary motion, or vice versa

the rack and pinion is used to convert between rotary and linear pinion is

used to convert between rotary and linear motion. Rack and pinion can

convert from rotary to linear motion. Rack and pinion can convert from

rotary to linear or from linear to rotary. The diameter of the gear determines

the speed that the rack moves as the pinion A Rack and pinion gear system is

composed of two system of cars to convert the rotary motion to the steering

gears. The normal helical gear is the pinion gear and the wheel to the side to

side motion in the wheel straight helical gear is the rack. The rack has teeth

cut into A rack and pinion consists of a pinion engaging and it and they mesh

the teeth of the pinion gear. Rack and transferring motion to or from a
 special kind of spur gear, pinion gear provides a greater feedback and

steering called a rack, consisting of a series of teeth in a straight sensation

1.1 FOREWORD

Rack & Pinion Type Passenger cum Material Lift, as the name implies, is basically

a lift with rack & pinion arrangement, for vertical transportation of passengers and

materials at the site of construction. No machine room, no lift shaft, no wire ropes

and no counterweights are required in these lifts. As such, much lesser time is

required for erection /commissioning of these lifts. Maintenance cost of these lifts

is also low as compared to the conventional wire rope type lifts. It is very useful

for high speed elevation of work men, supervisors, engineers, construction

materials, tools, tackles etc. for construction of multi storey buildings and high rise

structures. It may be of single cabin type or of twin cabin type. In twin cabin type

lifts, two cabins operate on the same maststructure.In view of the increasing use of

Rack & Pinion Type Passenger cum Material Lift at construction projects of multi

storey buildings, chimneys and other high rise structure sand also in view of the

fact that manufacture of such lifts has already been started in the country by some

of the manufacturers, it is considered necessary to lay down standard for this

equipment. The purpose of this standard is to set forth minimum requirements in

tended to provide for the safety of life, limb and property of those engaged in
occupations requiring the use of personnel hoists or employee elevators. This

standard applies to the design, manufacture, installation, operation, inspection,

Testing, maintenance, alterations and repair of hoists and elevators that are not an

integral part of buildings, are installed inside or outside buildings or structures

during construction, alteration, demolition or operations and are used to raise and

lower workers and other personnel and material connected with or related to the

structure. For the purpose of deciding whether a particular requirement of this

standard is complied with, the final value, observed or calculated, expressing the

result of a test or analysis, shall be rounded off in accordance with IS 2 : 1960

‘Rules for rounding of numerical values (revised)’. The number of significant

places retained in the rounded off value should be the same as that of the specified

value in this standard.

 CHAPTER-2

2. CONSTRUCTION FEATURES

“Rack & Pinion Type Passenger cum Material Lift” (fig. 1A and 1B for typical

sketch) shall consist of the following major assemblies:

 Base frame: the lowest framework of the hoist, upon which all other

components are mounted.

 Rack and pinion: a Lift which uses a toothed rack and pinion as the load

suspension system.
 Mast: structure that supports and guides the cabin and the counterweight

(when provided).
 Mast section: indivisible piece of mast , between two adjacent mast joints

Mast tie: a connection system between the mast and any building structure,

providing lateral support for the mast .

 drive and skip unit Safety device cabin control panel and electrical) winch

mast The design of mechanical components of the lift (i.e. base frame, mast

& rack assemblies, skip unit, cabin, anchoring brackets etc.) shall be safe

enough to ensure its safe operational maximum wind velocity of 20 meters

per second.
 CHAPTER-3

3.BASE FRAME

The base frame shall be a heavy duty steel structure fabricated from

Channel sections conforming to IS 2062.

Compression springs shall be provided on the base frame for cushioning effect

during descending and to provide extra lifting force while ascending. A typical

sketch of the base frame is given in fig. 2below:

3.1 MAST AND RACK ASSEMBLIES

3.2.1 LEGGED MAST

Fabricated from Square hollow steel section of suitable size conforming to IS

4923. However with Specific agreement between the purchaser and the

manufacturer, the mast structure May be of three legged type or four legged type,

fabricated from steel pipes of suitable size conforming to IS 1161.

3.2.2 SUITABLE ISA OR ISMC CONFORMING

to IS 2062 and / or steel pipes conforming to IS 1161 shall be welded with the

above referred mast module, as cross structural members, for improvement of its

bending and compressive load capacity.

3.2.3 RACK

Shall be machined from hot rolled / cold drawn steel bars of grade 45C8

Conforming to IS 5517. The profile of teeth of the rack shall match with the profile

of teeth of pinion explained in section 3(c) under the heading “Drive (2 Nos.) and

Skip Unit”. The rack shall be heat treated to achieve its hardness of 160 (plus 10

minus 0) BHN.
 CHAPTER-4

4. DESIGN CALCULATIONS

Design Calculations: =11×5

Design of Rack: =55mm

Rack-Cast iron 5.Vs=V1÷cos tan =z÷q

Pinion-Cast iron

u<390 N/mm² =0.14÷cos15.25° =3÷11

b =30 N/ mm² =0.145m/s lead

4.1 CALCULATION OF CENTRE DISTANCE

Corresponding Number of Starts: V1=pitch line velocity of rack

Z= 3 = d1n1÷(60×1000)

Z= iZ = ×55×50÷(60×1000)

24×3=72 =0.1439m/s

Check Whether Z Lies Between 25 and 85 SINCE Vs < 4m/s, the [ c] is correct

Choose q=11 the pinion

Assume( c ) =159 N/mm²

Assume initially kkd=1 V2=rack speed(rpm)×lead÷(60×1000)

Wheel torque= power × 60÷2 × rpm of the pinion = 50×(2 mx)or zpa÷(60×1000)

=50×3× ×5÷(60×1000)

=50×60÷2 ×(50÷24) =0.03m/s

= 229 Nm

[Mt] =ko.kd.Mt

=1×1×229×10³ =1×1×229×10³

=229×10³ Nmm =229×10³

a =[(z÷q)+]³v[(540÷(z÷q)[ c] ]².[Mt]÷10

=[(72÷11)+1]³v[540÷(72÷11)×159.[229×10³÷10]
4.2 DETERMINATION OF INDUCED STRESS

=7.56³v(0.518867)²×(229×10³)÷10

=7.56×18.336 c=540÷(z÷q)v[((z÷q)+1)÷a]³.[Mt]÷10

=139mm =540÷v[(72÷11)+1)÷207]³.229×10³

Calculation of Axial Module =86.9N/mm²<[ c]=159N/mm²

Mx=2a÷(q+z) =1.9×229×10³÷(5³×11×72×0.499)

=2×139÷(11+72) =8.80N/mm²<[ b]=30N/mm² Zeq=z÷cos³

=3.3mm =72÷cos³15.25°

Take mx=5mm (standard) yv =0.499(for 80 teeth)

angle = 15.25°

REVISE k,kd and [Mt] for the actual pitch line velocity of

Since V2=0.03m/s<3m/s, kd=1

Basic Dimensions: =370+(1.5×5)

Rack: =378mm

L =(12.5+0.09 Z)MX Root diameter of the pinion

=(12.5+(0.09×72)15 df2=(z-2)mx-2c

=284mm

L1=L+35(grinding allowance) =(72-2)5-(2×0.3×5)

=284+38

=319 Specification of Rack:

Number of Threads on Rack Material- Cast iron

=L1÷ mx Cross section=58×25mm

=319÷( ×5) Teeth on the rack is adjusted for

=21 86mm

4.3 ACTUAL LENGTH OF RACK SPECIFICATION OF PINION

=21× ×5 Material-Cast iron

=330mm Outside diameter=58mm

Pitch diameter of the rack=55mm Circular pitch=4.7mm

Tip diameter da=d1+2mx Pressure angle=21°

=55+(2×5=65 Ded endum=1.8m

Root diameter df1=d1-2mx-2c Fillet radius=0.45mm

=55-(2×5)-2×(0.3×5)

=42 Expected Load Can Handle:

Design of Pinion P=mgh÷t

Face Width of the Pinion

b =0.75 d1

=0.75×55 =38.4

=42 M=?

Pitch circle diameter of pinion,d2=zmx g =9.8

=72×5 m =P×t ÷gh

=360mm =(38.4×5)÷(9.81×0.45)

Tip diameter of the wheel,da2=(z+2)mx

=(72+2)×5

=370mm Therefore to conclude, we have designed and

Maximum pinion diameter de2=da2+1.5mx are done. Rack and pinion mechanism

are introduced in

=347mm

Module=1.5mm

Pitch circle diameter=55mm

Module=1.5mm

Addendum=1.5mm

Circular tooth thickness=2.35mm

Clearance=0.375

The power getting in pinion after all reduction

t =5sec(assumed)

h =45cm(assumed)

=43.49kg(including rack weight)

 CHAPTER-5

5. WORK DONE

We have designed and fabricated Rack and steadily worn away. This is because

compared to And Pinion Lift and further calculations are done. Rack the material

being ground, the abrasive is harder. and pinion mechanism are introduced in

lifting The grinding wheel actually acts like many hundreds of mechanism. very

small lathe bit, each cutting off some metal. The major operations done in design
and fabrication the abrasive must be strong enough to bear any kind of a rack and

pinion lifts are as follows:

 Cutting
 Drilling
 Welding
 Grinding

5.1CUTTING

Cutting operations are done so as to make the called a rack, consisting of a series

of teeth in a straight materials in proper dimensions. The cutting operations are

line on a flat surface The rack and pinion changes done by the various cutters

available in the market just linear motion into rotary motion, or vice versa. Liked

Walt, black decor etc. hack saw are used for soft In a rack and pinion lift system,

comprising a lift car, iron parts such as stainless steels

5.2 DRILLING:
Drilling is a cutting process that uses a drill bite control buttons set including

floor call buttons, call to cut or enlarge a hole in solid materials. The drill bit is a

Button units on landings along said mast, means multipoint, end cutting tool. It

cuts by applying pressure connecting said call button units to said control unit and

rotation to the work piece, which forms chips at the via a ground level unit, the

improvement comprising. Cutting edge

5.3 WELDING:

Welding is a process for joining differentDriving said car along a lift mast via rack

and pinion materials. Welding joins different metals or alloys with the means, a

control unit in said car with a control button set help of a number of processes in

which heat is supplied including floor call buttons; call button units on landings

either electrically or by means of a gas torch. Heat and along said mast, means

connecting said call button units pressure are the important requirement in

welding. to said control unit via a ground level unit.Micro computer controlled

floor call systems are Welding is classified into;earlier known in connection with

fixed wire rope hoist systems for indoor applications.

5.3.1 GAS WELDING:

It is a fusion welding process. it joinscases. power mains voltage variations often

occur due to metals using the heat of combustion of and oxygen/air connection and

disconnection of great loads and also the and fuel gas mixture. The intense heat

thus produced risk for voltage disappearance is greater than normal. melts and

fuses together the edges of the parts to be The above mentioned problems can

certainly in some welded, generally with the addition of a filler me .cases be

remedied by suitable choice of components, but at the same time they necessitate a

far going .

5.3.2 GRINDING:

For material removal, the method used in simplification of the signal transmission

and its grinding is called abrasion. In other words, in grinding, an organization in

order to eliminate as many sources of error abrasive material rubs against the metal

part and clears oars possible because of environment removes tiny pieces of

material. The process implies that

5.3.3 WORK DONE:

e have designed and fabricated Rack and steadily worn away. This is because

compared toad Pinion Lift and further calculations are done. Rack the material

being ground, the abrasive is harder. And pinion mechanism is introduced in lifting

The grinding wheel actually acts like many hundreds of mechanism. Very small

lathe bit, each cutting off some metal. The major operations done in design and
fabrication the abrasive must be strong enough to bear any kind of a rack and

pinion lifts are as follows: forces acting upon it while grinding.

 CHAPTER-6

6. SIMULATION OF MANUAL RACK AND PINION STEERING

SYSTEM

Manual rack and pinion steering systems are commonly used due to their

simplicity in construction and compactness. The main purpose of this paper is to

design and manufacture manual rack and pinion steering system according to the

requirement of the vehicle for better maneuverability. Quantities like turning circle
radius, steering ratio, steering effort, etc. are inter-dependent on each other and

therefore there are different design consideration according to the type of vehicle.

The comparison of results shown using tables which will help to design an

effective steering for the vehicle. A virtual rack and pinion assembly can be created

using software like SOLIDWORKS and ANSYS.

6.2 STEERING WHEEL TORQUE CALCULATION

The torque required to rotate the steering wheel by the driver is called Steering

Wheel Torque (WT). The calculations for steering wheel toque as follows,

T = kingpin torque

W = axle weight

= 50 kg

= 120 lbs (the axle weight for every vehicle is different and it is not the total

weight of the vehicle)

‫ = ݑ‬co-efficient of friction

= 0.7 (assumed to be 0.7 for most of the road condition)

E = kingpin offset

= 55mm
= 2.1” B

= width of tire

= 7”

6.3 ANALYSIS OF COMPONENTS

Analysis is process of analyzing the components by applying load, temperature,

pressure etc. and obtaining the values such as stresses (bending, tangential and

normal), deformations, safety factor etc. in order to determine the safety of the

components when done in practical. These Analyses gives optimum result of safety

of components and minimize the chances of failure.

 Three major analyses of rack and pinion on Annoys 15.0 are carried out here:

1) Total Deformation

2) Equivalent Stress

3) Factor of Safety

A) TOTAL DEFORMATION

B) FACTOR OF SAFETY

C) EQUIVALENT STRESS

Material Type:
EN24 Ultimate Tensile Strength = 850
MPa Maximum Stress Obtained = 18.845
MPa Factor of Safety = 15
Maximum Deformation = 15.5757 x 10-4mm
Thus after the analyses of components The Design is Completely Safe.

CHAPTER-7

7. CONCLUSION
Therefore to conclude, we have designed and fabricated Rack And

Pinion Lift and further calculations are done. Rack and pinion mechanism is

introduced in lifting mechanism. Thus we came in to a contradiction that the

installation of a lift is not an easy task and high installation cost. As

compared with the other lifting mechanism, rack and pinion lift mechanism
does not need any separate machine rooms. Well designed Rack and pinion

lifts are more compact and saves effort and time.

REFERENCE
1). Prabhu, T.J., 2007. Fundamentals of Machine Design.
2). Rathan, S.S., 2004. Theory of Machines.
3). Bansal, R.K., 1999. Theory of machines
4). Rajput, R.K., 2003. Automobile Engineering.
5). Garg, S.K., 1990. Workshop Technology.
6). GUPTA, J.K., 2000. Workshop Technology.