CHAPTER ONE

INTRODUCTION
1.1. Background and Justification
This project deals with design and fabrication of car lifting machine with the help of hydraulic
cylinder. Lifting of the car when replacing wheel, changing and lubrication needed, maintenance
of different suspension system take. For this type of operation, we need jack which is simple to
operate and having high lifting capacity. For lifting cars in car service station hydraulic jacks
mostly used. High pressure liquid is filled in the jack cylinder by hydraulic pump, due to the
pressure the piston moves up. To lower the piston valve is provided by which the liquid returns
to the hydraulic tank. Hydraulic Jacks are portable devices used for raising heavy objects by
means of force applied with a lever or screw. The hydraulic jacks are compact and lightweight
units that are used for lifting capacities. They offer easy operation and fast acting components.
The hydraulic jacks come with inbuilt release pedal for rapid lowering and lugs that make it easy
to mount. The heavy chassis prevents the jack from twisting or bending and foot pump provides
fast lift to the load. It also has a safety overload valve that prevents overloading beyond rated
capacity. Unlike the traditional screw type jack which has to be turned with a long handle, the
hydraulic jack uses oil pressure to displace (lift) the vehicle by mere moving a lever or handle up
and down. This is very easy to operate and with this even a child can operate and lift a vehicle
using the hydraulic jack.

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1.2. Problem Statement
The problem I sew and tried to solve is the shortage of car lifting material from ground to some
height; which means there are three floor jacks but they are very old and they do not work (they
are out of work). But only one floor jack is left. This jack is also so many problems like:

-It is not work properly

-It has very high mass (about 200kg).

-It is difficult for one person to push or pull from place to place.

-All workers (when they need to lift the car) are wait jack to work with it b/c of the shortage of
it. Floor jack requires more effort moreover not suitable for uneven surfaces. It requires more
power consumption also Maintenance is quite high as well as Suitable for small capacity and
requires skilled power.

Figure 1 Oldest jack

The purpose of this project is to modify the design of existing car jack in terms of its
functionality and also human factors considerations. General idea of the project is to minimize
the human effort while operating the jack. To provide an inbuilt hydraulic jacking system that is
directly and permanently incorporated into the vehicle frame in such a way as to prevent the
additional risk of damage.

- It is a short stroke hydraulic lift which is fed from hand pump.

- It has low mass about

- It is easy for one person to push or pull from place to place. 2

- The number of jack is also increase. The hydraulic jack may be portable. This is extensively
used for lifting automobiles usually to facilitate and repair and for replacing the punctured wheel.
The hydraulic jack is perhaps one of the simplest forms of a fluid power system. By moving the
handle of a small device, an individual can lift a load weighing several tons. A small initial force
exerted on the handle is transmitted by a fluid to a much larger area.

The operation of hydraulic jack depends on ―Pascal law. This states that when a fluid is at rest
in a closed vessel and if a certain pressure is applied at any point the pressure will be transmitted
equally in all direction.

Figure 17 New designed hydraulic jack

Hydraulic System: There are six basic components

1. A tank (reservoir) to hold the oil

2. A pump to force the oil through the system 3

3. A power source to drive the pump (electric, others)

4. Valves to control oil direction, pressure, and flow

5. An actuator to convert the oil pressure into force (cylinders) or torque (motors).

6. Piping, which carries the oil from one location to another

1.3. Objectives
1.3.1. General Objective
General idea of my project is to design, fabricate and use a hydraulic jack as an inbuilt solution
for lifting the vehicle with control in the hand of driver.

1.3.2. Specific Objective

The specific objective of this project is

 Design of base frame

 Design of cylinder shell
 Design of plunger cylinder
 Design of reservoir and
 Design of plastic pipe

1.4. Scope of the project

This project focuses on the design of hydraulic jack .it includes some modification on the
existing jack in order to make it easy for use .the design and analysis of each components
;design of base frame ,design of cylinder shell, design of plunger cylinder ,design of reservoir
and design of plastic pipe of jack up to manufacturing.

1.5. Significance of the Project

The findings of this study will redound to the benefit of society considering that hydraulic jack
plays an important role in many activities of society .the great demand for this equipment
justifies the need for more effective life changing approaches.

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Problem related to effort will be avoided by the addition of hydraulic system. The cost of jack
will be solved by reducing over design, that means the design should be up to mark .I reduce the
product by converting manufacturing process, example casting into sheet metal, in which the
strength of the product remain the same and the cost of the material will be automatically reduce
,part reduction by assembly process and avoidance of much welding joints.

The design aims to reduce human force applied in the operating time of the jack and the need for
modification is to minimize different problems on existing hydraulic jack like efficiency, cost,
availability and other problem with the addition of very interesting and important modification.
Generally the scope of this project is to design each component of the hydraulic jack to reduce
human power needed to operate the jack and any other modifications to reduce weight of
hydraulic jack.

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 CHAPTER TWO

LITERATURE REVIEW
2.1. Introduction
A jack is a device that uses force to lift heavy loads. The primary mechanism with which force is
applied varies, depending on the specific type of jack, but is typically a screw thread or a
hydraulic cylinder. Jacks can be categorized based on the type of force they employ: mechanical
or hydraulic. Mechanical jacks, such as car jacks and house jacks, lift heavy equipment and are
rated based on lifting capacity (for example, the number of tons they can lift). Hydraulic jack
tends to be stronger and can lift heavier loads higher, and include bottle jacks and floor jacks.

HYDRAULIC JACKS depend on force generated by pressure. Essentially, if two cylinders (a

large and a small one) are connected and force is applied to one cylinder. Then equal pressure is
generated in both cylinders. However, because one cylinder has a larger area, the force the larger
cylinder produces will be higher, although the pressure in the two cylinders will remain the
same. Hydraulic jacks depend on this basic principle to lift heavy loads: they use pump plungers
to move oil through two cylinders. The plunger is first drawn back, which opens the suction
valve ball within and draws oil into the pump chamber. As the plunger is pushed forward, the oil
moves through an external discharge check valve into the cylinder chamber, and the suction
valve closes, which results in pressure building within the cylinder. Hydraulic jacks work on the
basis of Pascal's Principle, named for Blaise Pascal, who lived in the seventeenth century.
Basically, the principle states that the pressure in a closed container is the same at all points.
Pressure is described mathematically by a Force divided by Area. Therefore, if you have two
cylinders connected together, a small one and a large one, and apply a small Force to the small
cylinder; this would result in a given pressure. By Pascal's Principle, this pressure would be the
same in the larger cylinder, but since the larger cylinder has more area, the force emitted by the
second cylinder would be greater. This is represented by rearranging the pressure formula P=
F/A, to F = PA. The pressure stayed the same in the second cylinder, but Area was increased,
resulting in a larger Force. The greater the differences in the areas of the cylinders, the greater
the potential force output of the big cylinder. A hydraulic jack is simply two cylinders. 6
An enclosed fluid under pressure exerts that pressure throughout its volume and against any
surface containing it.

This project deals with design and fabrication of hydraulic car lifting attachment with the help of
hydraulic cylinder. Lifting the car in any problem case like replacing wheel, & when tyre is
puncture it is not easy. For this type of operation, we need heavy force. In the case of tyre
puncture or replacing wheels lift the car is more important part.

2.2. Literature survey

Blasé Pascal (2013) - have Worked on the principal of hydraulic power and operated by 12 Volt
DC current, solves the all major problem of maintenance of all automobiles specially the heavy
vehicles like truck and bus. Kenneth J. Waldron and Robert B. McGhee (1986) - provides a
description of the Adaptive Suspension Vehicle. The vehicle uses a legged, rather than a wheeled
or tracked, locomotion principle, and is intended to demonstrate the feasibility of systems of this
type for transportation in very rough terrain conditions. The vehicle is presently under test, with
installation and validation of software modules for different operational conditions scheduled for
com-pletion by the end of 1986. N.K. Mandavgade (2012) –studied that Automobile hydraulic
jack can be easily operated by a single push button provided on the dash board. The jack will be
installed on both the sides of chassis according to the weight distributions of the car. The system
operates on hydraulic drive which consists of three main parts: hydraulic pump, driven by an
electric motor, hydraulic cylinder to lift the vehicle. The car gets lifted and load gets distributed
on three point i.e., plunger or ram of hydraulic cylinder and two tires opposite to side which is
lifted. Dr. Ramachandra C G, Krishna Pavana, Shivraj Shet and Venugopal Reddy, Virupaxappa
B (2013) – have presented that whenever any vehicles undergo a tyre failure, it becomes a very
cumbersome task for the person to lift the vehicle from the ground level and lot of manual effort
is required even though a jack is used. Musa Nicholas, Abodunrin Tosin Oladipo Sarafadeen
(2016) - have studied that in order to mitigate the problems associated with the use of a single
jack and other lifting devices to raise cars completely off the ground to effect repairs. P. S.
Borkar, S. V. Sontakke, R. R. Dorwe, A. B. Ganorkar, S. P. Lokhande (2015)-have studied
application of pressurized air to produce mechanical motion. Pneumatic jack is a fabricated
model which when installed in four wheeler, will ease in the problems arising in the conventional
operated jack. Balkeshwar Singh, Anil Kumar Mishra.(2015) . 7
This modification of the existing motor screw jack by incorporating an electric motor in the
screw in order to make load lifting easier. In this modified design, the power screw is rotated by
connecting motor through universal coupling, plugged to the automobile 12 V battery source to
generate power for the prime mover (motor), which transmits its rotating speed to the power
screw to be rotated with required speed reduction and increased torque to drive the power screw.
Mohammed Siddique Ahmed, Mohd RiyazUddin, Faraz Ur Rehman Azhar, Md Shaffi ( 2014 )-
A jack is a device that uses force to lift heavy loads. The primary mechanism with which force is
applied varies, depending on the specific type of jack, but is typically a screw thread or a
hydraulic cylinder. Jacks can be categorized based on the type of force they employ: mechanical
or hydraulic. Mechanical jacks, such as car jacks and house jacks, lift heavy equipment and are
rated based on lifting capacity (for example, the number of tons they can lift). Hydraulic jack
tend to be stronger and can lift heavier loads higher, and include bottle jacks and floor jacks.

8
 CHAPTER THREE

METHODOLOGY OF THE RESEARCH

3.1. Planning methods

To accomplish our design, I have used the following methodologies.

1. Problem identification

From our view, we have selected the title of our project. The title of the project is Design of
Hydraulic jack. Then preparing reasonable questions for which it concern were my habitual
characteristic. This is in order to gather important information about over all of the company.
Every day, (during intern period) I had been observing how things were going on.

2. Gathering possible solution for the problem

To search data under this method I read different written documents from the library of the
company. This step is the point where I make an attempt to generate solutions based on what I
have learnt in the academic courses. I used here my theoretical knowledge and other important
information searched from different sources. Every day I submit my ideas about how to
overcome the problems encountered in the company for department head and we discuss on what
is written. After understanding the written materials, the department foreman accepts some
solutions that would have been possible to apply at the company level.

3. Apply the solutions practically

As much as possible, accepted solutions are applied with in short period of time. Some
photographic picture, as presented under the following sub-title, shows the results of practically
applied solutions.

3.2. Data collection methods

Collecting data using primary and secondary sources

Primary sources of data collection 9

Interview: -during practical work, preparing reasonable questions for whom it concern. This is
in order to gather important information about over all of the company.

1. What is the reason that these much machines are out of use?

2. Is there any maintenance manual based on which you are restoring machine that are
damaged?

3. From which country the company is buying spare parts?

Observations: -everyday during intern period I had been

Secondary sources of data collection:

To search data under this method I read different written documents from the library of the
company. In addition to this I used web search related with Arbaminch textile Share Company,
about maintenance

3.3. Idea generation methods

In this step I jot down all the important points that can be the possible solutions for the problems
that I faced in the company. This step is the point where I make an attempt to generate solutions
based on what I have learnt in the academic courses. I used here my theoretical knowledge and
other important information searched from different sources. The possible solutions were,
applying standardized and modernized maintaining system of machines, implementing
continuous improvement (kaizen), and 5S. if cost effective design new machine

3.4. Evaluation methods

Evaluation manly focused on;

1, Strength 3, impact and fatigue resistance

2, Availabilities 4, manufacturability 5, Cost 6, efficiency 7, Durability

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 CHAPTER FOUR

DESIGN PROCESS
4.1. Recognition of need
It is unquestioned to have lifting machine in garages. Lifting the car in any problem case like
replacing wheel, & when tire is puncture it is not easy. For this type of operation, we need heavy
force. In the case of tire puncture or replacing wheels lift the car is more important part. This
time we use traditional ways to lift the tire. In that case a physically handicapped person, aged
person not lift the tire easily. They require more time and also require more force to lift the tire.
Automatic hydraulic jack system is more useful for this type of problems.

4.2. Definition of problem

The problem I sew and tried to solve is the shortage of car lifting material from ground to some
height; which means there are three floor jacks but they are very old and they do not work (they
are out of work). But only one floor jack is left. This jack is also so many problems like:

-It is not work properly

-It has very high mass (about 200kg).

-It is difficult for one person to push or pull from place to place.

4.3. Analysis
 Force analysis of the overall parts is basic and important for the stability and knowing
the overall force transmitted to the hydraulic jack.
 It is the resistance offered by a material when subjected to external loading. So, stronger
the material the greater the load it can withstand.
 Depending upon the type of load applied the strength can be tensile, compressive, shear
or tensional
 Since the frame material is metal which is made up of Medium Carbon steel with:-
- Carbon content of 0.30-0.50%
- BHN No of 150-350
- Tensile Strength of700-770mpa
- Yield strength of 550-580mpa 11
 - Percent elongation of 18-20% - Percent reduction area of 51-53
- Modulus of elasticity 200-200GPa or GN/m² or KN/mm²
- Modulus of rigidity (C) 80-100GPa or KN/mm²
- Factor of safety:-For steady load 4
-For Live load 8
-For shock load 12 to 16
- Poisson’s ratio 0.25to 0.33

4.5. Design calculation

Force Analysis
INPUT DATA
To calculate the force that applied on the smallest frame that found on the top of six
cylinders, we take the maximum weight of the Toyota car.
m =1380kg
g = 9.8lkgm/s²
Modulus of elasticity 200-200GPa or GN/m² or KN/mm²
Modulus of rigidity (C) 80-100GPa or KN/mm²
Factor of safety:-For steady load 4
-For Live load 8
-For shock load 12 to 16

Now let as calculate the force acting on the reaction of the weight at equilibrium.

∑ =0 the force and momentum summation =0

∑ =0

4.6 DESIGN ANALYSIS

4.6.1 Mechanical Properties and Its Application
Force analysis of the overall parts is basic and important for the stability and knowing the
overall force transmitted to the hydraulic jack.
Since the design should be done on the maximum loads, we should specify the maximum
load for the car.
 CHAPTER FIVE
CONCEPT DEVELOPMENT
5.1. Introduction

Hydraulic jack is very important device for lifting of heavy loads so maintenance can be
performed easily .but most old hydraulic jack is difficult to move, low lifting capacity and
expensive .as we all know this jack is not manufactured in Ethiopia, it is imported still now and
result negative economic impact in my country .so it must design and manufactured here by
using available material with cost minimize and high efficiency.

5.2. Idea generation

Floor jack requires more effort moreover not suitable for uneven surfaces. It requires more
power consumption also Maintenance is quite high as well as Suitable for small capacity and
requires skilled power and expensive. This problem I sew and I have to try to solve the problem
in two ways;

1. By maintain or modified the old jack

2. By design the jack by adding some futures

5.3. Evaluation of ideas

The first choose which I mention above is temporary solution not terminate the problem it may
useful for time being but it is not permanent solution .the second choose is most appropriate in
many aspect like

 it is simple to operate
 it is easily portable
 it has small Wight relative from old one
 it is not expensive
 it has high durability and
 it is endemic product which minimize or stop import of foreign jack

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 5.4. Concepts

Idea + energy + material = overall function = out put

Design of base frame

Design of ram cylinder

Design of plunger
cylinder

design of reservoir

Design of plastic
pipe

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 CHAPTER SIX
RESULTS AND DISCUSSIONS

6.1 Results of the Design Procedure

After I perform all design, force that applied on the base frame, the sum of force of the car,
circular tubes, the upper frame, thin cylinder (fluid tank), pumping cylinder, and the pumping
cylinder supporter.it is around 13704.38 N. Frame is made up of mild steel. Permissible tensile
strength of mild steel ( ) = 120 N/mm2; The design is safe because induced shear and
compressive stresses are less than permissible valve. Hence compressive strength = 3.339
N/mm2, shear strength τ =17.83 N/mm2.

Six equal cylinders with equal radius, height, volume and area which the force is equally
distributed over them. Also, equal pressures are acting on them. The ram cylinder is made up of
mild steel with density of 7.868 gm/cc. They are mounted on the base plate. The volume of all
cylinders is the same, it is 43008mm³. The plunger cylinder is made up of mild steel and is
mounted on the base plate. It provides slide way to the plunger in order to build up the pressure.
Its diameter Inside of plunger cylinder = 8 mm and Outer diameter of plunger cylinder (DP) = 18
mm

The reservoir is Consider as a closed thin cylindrical shell subjected to an internal pressure. A
tensile stress acting in the direction of the axis is called longitudinal stress. The longitudinal
stress is 1518 and the maximum shear stress is 1138 its volume is 0.286m³. The stresses

in pipes due to the internal fluid pressure are determined by Lame's equation the maximum
tangential stress at inner surface of the pipe is 1462.2 and minimum tangential stress at outer

surface of the pipe is 981.3 .

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6.2 DISCUSSIONS
Hydraulic jack consists of a cylinder and piston mechanism, in which the movement of the piston
rod is used to raise or down the load. Hydraulic jacks are typically used for shop work, rather
than as an emergency jack to be carried with the vehicle, and it uses liquid instead of screw. A
hydraulic jack uses a fluid, which is incompressible, that is forced into a cylinder by a pump
plunger. There are many subcategories of hydraulic jack some of these are, farm, strand, bottle,
pneumatic etc.

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 CHAPTER SEVEN
CONCLUSION AND RECOMMENDATION

7.1. Conclusion
Finally, using this jack practically, it will be an easy task to lift and lower the load with less
energy end with in a short time. This is an important machine for the company, this is due to
large number of moenco cars are getting minor and major services per day regarding to different
system maintenance. . Hydraulic jack are the ideal product to push, pull, lift, lower and position
loads of anything from a couple of kilograms to hundreds of tones. The need has long existed for
an improved portable jack for automotive vehicles. It is highly desirable that a jack become
available that can be operated alternatively from inside the vehicle is located.

7.2. Recommendation
As it is known for everyone, the world is coming from time to time predominately use Hydraulic
jack. So, this power paves a way for this company in using similar machines taking in to
consideration the heaviness of the work. So here are some recommendations

 Improper use of this jack will lead cylinders faller and frame breaking so we kindly
recommend that the company should give emphasis on the proper use of the equipment
by giving required training and awareness for the technicians.
 Unnecessary applied force on the jack may damage the system of the machine.
 moving a jack form one place to another in workshop properly

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