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Design and Fabrication of Inbuilt Hydraulic Jack for Four Wheelers

Article · September 2020

DOI: 10.5281/zenodo.4041017

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 Recent Trends in Automation and Automobile Engineering
Volume 3 Issue 2
DOI: http://doi.org/10.5281/zenodo.4041017

Design and Fabrication of Inbuilt Hydraulic Jack for Four

Wheelers
Prashant D.Banakar1*, Prashantakumar N. K.2*, Hanumesha Pujar3
Department of Mechanical Engineering, K.L.E. Institute of Technology, Hubballi,
Karnataka, India
*Corresponding Author
E-Mail Id: [email protected]

ABSTRACT
The aim of this work is to design and develop an inbuilt hydraulic jacking mechanism that
can be operated by the driver from inside the vehicle. Separate buttons are provided in order
to raise or lower the right and left side jacks. By pushing the given button in the dashboard,
the inbuilt self-jacking component gets initiated. This paper manages the plan of fabrication
of this system. By using this technique we can attain less power loss and simple design. The
load will be distributed in three ways: plunger of hydraulic cylinder and two tires are lifted
which will in opposite side. Jack can be installed on the either sides of chassis as per the load
distributions of the four wheeler. The system actuate separately for either side of four
wheeler as per the breakdown condition. The v gets is lifted and load is distributed on three
point’s. The inbuilt hydraulic jack will be valuable to the senior residents and for women who
discover it incredibly hard to work the jack physically in any breakdown of the vehicle. This
hydraulic jack will have the option to lift the wheels as indicated by our prerequisite that is
on the off chance that we need to lift just two wheels, at that point it tends to be finished by
moving the cylinder as needs be on the rack with the assistance of the DC motor. Assume on
the off chance that we need to lift all the four wheels of the vehicle; at that point it tends to be
finished by discovering the centre of gravity.

Keywords: Hydraulic Jack, Pneumatic System, Plunger

INTRODUCTION jack, floor jack or garage jack which lifts

The Hydraulic Jack is the gear which is the vehicles. The hydraulic jack is that the
utilized to lift the four-wheelers with the normal type of jacks utilizing for lifting
assistance of liquid (oil), hydraulic the vehicles. Various improvements are
cylinders, solenoid valves pump and carried out with current hydraulic jack
engine. The utilization of this jack lessens with different electronic devices. With the
human force definitely and spares gigantic help current technology the priority will be
time during the puncture of the tyres and given for safety, luxury and comfort.
vehicle breakdown. The liquid utilized Hydraulic jack is works on the principle of
ought to be in-compressible so the Pascal’s law. The jacks which are
equipment may withstand the heaviness of available in the market are time consuming
the vehicle.[8,9] and require more effort.[3,4]

Inbuilt Hydraulic Jack consists of the LITERATURE SURVEY

following parts hydraulic cylinders, AC This work is inspired by journal papers
motor, DC motor, pump, solenoid valves published in three international journals.
and hoses. A jack may be a robot used as These journal papers emphasized on the
device to lift heavy loads or apply great use of dc motor, joined with lead screw
forces. The most commonly used is car and hydraulic cylinders for lifting the

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 Recent Trends in Automation and Automobile Engineering
Volume 3 Issue 2
DOI: http://doi.org/10.5281/zenodo.4041017

vehicle to reduce the human effort. Hence, surplus manual effort and time. This
hydraulic lift results in easy and safe mechanism overcomes these
operation. disadvantages. By pressing the button
provided in the dashboard the jacking
Aditya Masiwal, et al.[1] [2018] an mechanism gets activated.
Experimental investigation of Fabrication
of Inbuilt Hydraulic Jack for Four METHODOLOGY
Wheelers, International Journal of The method used here is automatic which
Research in Engineering and Technology. replaces manually operated screw jack.
This paper explains that this project not For the fabrication we use Mild Steel
only saves human effort but also reduces frame (1inch × 1inch) by using arc
the replacement time during the time of welding joining process on which all the
puncture. Lifting capacity is more in parts are mounted. We casted two pulleys
hydraulic jack in comparison with for power transmission from AC motor to
pneumatic. the vane pump, the pulley in the ratio of
1:9. Attached the four nylon wheels to the
R. Sabarish et al.[2] [2017] an frame by using two axels and axels
experimental investigation of Fabrication supported by the four ball bearings. AC
of Inbuilt Hydraulic Jack for Four motor mounted one side on the frame by
Wheelers, in International Journal of Pure using fasteners and vane pump placed
and Applied Mathematics. This paper another side of the frame with the help of
concludes with the well advanced fasteners. Here we use two 2/2 solenoid
operation of hydraulic jack overcoming the valves for oil flow control these also
manual operation of screw jack used in mounted on the frame. Two MS plate box
most of the auto service centers. structures used for placing the oil reservoir
and battery at front and back side of the
R. Sharavanan et al. [2] [2017] an frame. We made the sliding passage for
experimental investigation of Fabrication the movement of the cylinder on the frame
of Inbuilt Hydraulic Jack for Four on which the cylinder slides with the help
Wheelers in International Journal of of DC motor the rotary motion of the DC
Mechanical Engineering and Technology motor is converted linear motion of slider
(IJMET). The research survey revealed by using the rack and pinion arrangement
that few methods were adopted to lift the mounted on the frame. Here we use two
vehicle for reconditioning, repairing et al. push button for controlling the two
Here they have mainly focused on solenoid valves separately. Hoses are used
difficulty in operating the hydraulic jack. to connect the vane pump, oil reservoir,
solenoid valves, and cylinder for the oil
Mayank Agrawal, et al [5] [2018]. A flow.
“Design and fabrication of hydraulic jack”
an International Research Journal of COMPONENTS AND DESCRIPTION
Engineering and Technology, This paper is The major components involved in the
regarding the planning of fabrication of Fabrication Inbuilt Hydraulic Jack for Four
self-jacking mechanism in four wheeler Wheel as follows.
cars. Driving a car in quite common now 1. Frame
days, whereas tyre failure during the 2. AC motor
journey is also quite common and 3. Pulley
unexpected. In such condition lifting of car 4. Vane pump
from the ground surface using a 5. Cylinder
mechanical jack is a big task. This requires 6. Push buttons

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 Recent Trends in Automation and Automobile Engineering
Volume 3 Issue 2
DOI: http://doi.org/10.5281/zenodo.4041017

7. Wheels AC Motor
8. Solenoid valve
9. DC motor
10. Reservoir
11. Hose Pipes
12. Toggle Switch
13. Battery
14. Rack and pinion

Frame

Fig. 2: AC Motor.

AC Motor is an electric gadget which

changes over electrical energy into the
mechanical energy. The AC Motor
comprises of stator and rotor and driven by
an alternating current. It is used to run the
vane pump. The smaller shaft of the pulley
is connected to the AC Motor. It is used to
transmit the power through pulley to the
pump with the help of the V belt.
Fig. 1: Frame.
Pulley
Frame is made up of mild steel material. It
is the main supporting structure of the
model. All parts are mounted on this frame
structure with the suitable arrangement. It
is compared to the skeleton of an
organism.

The material used i.e., mild steel, is a pipe

which is square in shape and hollow. It has
to deal with the loads without undue
deflection or distortion. It consists of rack
on which pinion consisting of cylinder and
DC Motor slides. Two axles i.e., front and Fig. 3: Pulley.
rear, are mounted on the frame to which
the wheels are connected. A pulley is a wheel on an axle or shaft that
The main functions of a frame are: is designed to support movement or
1. To support the mechanical transfer of power. Two pulleys are used
components and body here. The drive element of pulley system is
2. To deal with static and dynamic loads, V belt. One pulley is of bigger diameter
without undue deflection or distortion. which is mounted on the pump shaft and
3. These include: the other is of smaller diameter which is
mounted on the motor shaft.

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 Recent Trends in Automation and Automobile Engineering
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DOI: http://doi.org/10.5281/zenodo.4041017

Vane Pump It is a simple switch mechanism for

controlling a machine or process. There
are two push buttons. They are used to
actuate the solenoid valve. They are
connected to the 240V power supply.
Pressing, depressing, mashing, slapping,
hitting, and punching are most commonly
used terms in pushing of button? Buttons
are made up of hard material, usually
Fig. 4: Vane Pump. plastic or metal.

This is a positive displacement pump Wheels

consists of vanes mounted on a rotor
which rotates inside a cavity. Pulley of
larger diameter is mounted on the pump
shaft. It has a circular rotor rotating inside
a larger circular cavity. The focuses of
those two circles are offset, causing
eccentricity.

Single Acting Cylinder

Fig. 7: Wheels.

Fig. 5: Single Acting Cylinder. There are four wheels present in the model
which made up of nylon. They are of 8
Here we make use of single acting spring inches in diameter. They are mounted on
return cylinder. Single acting cylinders the axles supported by the bearings.
even have a spring inside the cylinder. It
works with the assistance of packed gas to To move the heavy loads we need to rotate
incite the piston single way and the wheels on the horizontal axle and to
utilizations spring force to come back to regulate the spinning motion we need to
the base position. As soon because the air turn on its vertical axle
supply is stop, the connecting rod retracts
by spring force. Solenoid Valve

Push Buttons

Fig. 6: Push Buttons. Fig. 8: Solenoid Valve.

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This is an electro-mechanical gadget can be called as a storage part of the

which utilizes an electrical current to get a model. The storage capacity of the
magnetic flux and afterward manages the reservoir is 2 liters. The supply of the
opening of liquid stream inside the valve. hydraulic oil takes place from the
Here we make use of two 2/2 solenoid reservoir.
valves. One solenoid valve is used for the
extension of the cylinder where the Hoses
hydraulic oil flows from the reservoir to Hoses are used for the transferring of the
the cylinder through the hose pipe, hence hydraulic oil from one part to the other in
lifting the jack. Other solenoid valve is the hydraulic jack starting from the
used for the retraction of the cylinder reservoir. The hoses used must be strong
where there the hydraulic oil flows from enough for the smooth transfer of the
the cylinder to reservoir through the hose hydraulic oil. The shape of a hose is
pipe, hence the jack comes down. typically cylindrical (having a circular
cross section).
DC Motor
Hoses are likewise called pipes however
lesser inflexible than pipes. In light of a
necessary application and execution the
hoses will be structured. Size, pressure
rating, weight, length, straight hose or coil
hose, and chemical compatibility are most
regular elements identified with
hoses.[6,7]

Toggle Switch
Fig. 9: DC Motor.

A DC motor is a device which converts

DC electricity into energy. DC Motor
drives the pinion on the rack present in the
frame.

Reservoir

Fig. 11: Toggle Switch

It is an electrical switch which is incited

physically utilizing a mechanical switch,
handle, or rocking mechanism. Toggle
switch used in the hydraulic jack is used to
make the cylinder move on the rack which
is driven by the DC motor. This toggle
Fig. 10: Reservoir. switch can be moved in three directions,
i.e., forward, rest and backward movement
A reservoir is facilitated in the hydraulic of the cylinder respectively.
jack in order to store the hydraulic oil. It

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 Recent Trends in Automation and Automobile Engineering
Volume 3 Issue 2
DOI: http://doi.org/10.5281/zenodo.4041017

Battery rotary motion of the DC motor in to the

linier motion of the cylinder on sliding
mechanism for positioning of the cylinder
for different positions..

Hydraulic oil
A hydraulic fluid or hydraulic liquid is the
medium which moves power in hydraulic
machines. Mineral oil or water is the most
commonly used fluids. Excavators,
transmissions, hydraulic brakes, power
steering systems, aircraft flight control
Fig. 12: Battery.
systems, lifts and industrial machinery are
the examples where we use the hydraulic
The battery used in the hydraulic jack is of
fluids.
12V and 7.2amps. It is used to drive the
DC motor which is used to run the
For our experiment purpose we have used
cylinder containing the pinion on the rack.
hydraulic oil with grade 46 which is made
out of top notch dissolvable refined base
Rack and Pinion
oils. It is liberated from debris making
It is mechanical gadget which comprises
parts, silicone and zinc, additionally have
of a rectangular bar called as rack which is
generally excellent anti- wear and anti-
having teeth on one side that networks
corrosion properties, awesome oxidation,
with teeth on a little apparatus called as the
thermal stability and water division
pinion. The pinion might be comprises of
qualities.
straight teeth or helical teeth. Here we
used rack and pinion for converting the

Table 2: Component Specification

Sl No Component Specifications
Material Mild Steel
1. Frame
Size 16inch*34inch
Input Power 1HP
Input Voltage 240V
2. AC Motor Current 2.8A
Head 25m
Speed 1440rpm
Diameter of bigger pulley 225mm
3. Pulley Diameter of smaller pulley 50mm
Centre distance 245mm
Max. Pump Pressure 50bar
Rotor Diameter 30mm
4. Vane Pump Cam Ring Diameter 50mm
Width Of Vane 20mm
Eccentricity 10mm
Outer diameter 45mm
Inner diameter 38mm
5. Cylinder
Stroke length 60mm
Thickness 3.5mm
material Nylon
6. Wheel
diameter 8 inches
Voltage 12V
7. Battery
Current 7.2Amps

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 Recent Trends in Automation and Automobile Engineering
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DOI: http://doi.org/10.5281/zenodo.4041017

DESIGN AND MODELLING P = 670.166 watt

Calculation of the Power capacity AC P = 0.670 Kw
Motor P = 0.898 hp
Here we are considering to lift So that we are using 1 hp power capacity
approximate load 560kg = 5600N AC Motor

Diameter of cylinder Power Capacity of DC Motor

F=P×A Calculation of force
5600 = 5 × 𝜋𝑟 2 F= 𝑚 × 𝑎
r = 18.88 F = 15 × 9.81
d = 37.76 mm ≅ 38 mm F = 147.15 N
∴ Inner Diameter of the cylinder = 38 mm
Calculation of torque
Volumetric displacement of vane pump T = F× r
𝜋
VD = 2 [ dc + dr ] e × l T = 147.15 × 0.0435
𝜋 T = 6.40 N-m
VD = 2 [ 50 + 30] 10 × 20
So that we are using 10N-m torque
VD = 2.5132 × 102 mm3 capacity DC Motor.
VD = 2.513 × 10-5 m3
Calculation of CG
Discharge of vane pump
QT = VD × N
QT = 2.513 × 10-5 × 320
QT = 8.042 × 10-3 m3/min

Pump torque
Here we are assuming the mechanical
efficiency of pump is 100 %
𝑃×𝑄𝑇
ηm = 𝑇𝑝×2𝜋𝑁
50 × 10^5 ×8.042 × 10^−3 Fig. 13: Centroid.
1= 𝑇𝑝 ×2 𝜋×320
Tp = 20 N-m Area = b × l
Area = 406.40 × 863.60
Motor torque Area = 350967.04 mm2
The power from motor is = the power to Location of centroid with respect to the Y
the pump axis is given by
Assuming there is no power loss 𝑎𝑥
X= 𝑎
350967.04 ×203.2
2𝜋𝑁𝑇𝑚 2𝜋𝑁𝑇𝑝 X = 350967.04
=
60 60
2𝜋×1440×𝑇𝑚 2𝜋×320 ×20 X =203.20 mm
= Location of centroid with respect to the X
60 60
Tm = 4.44 N-m axis is given by
𝑎𝑦
Y= 𝑎
Power capacity of AC Motor 350967.04 ×431.8
2𝜋𝑁𝑇𝑚 Y=
P = 60 350967.04
2𝜋×1440×4.44 Y = 431.80 mm
P= 60

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 Recent Trends in Automation and Automobile Engineering
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Two Dimension (2D) Drawings

Fig. 14: Two Dimension (2D) Drawings.

Three Dimensional (3D) Model

Fig. 15 (a): Three Dimensional (3D) Model View 1.

Fig. 15 (b): Three Dimensional (3D) Model View 2.

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 Recent Trends in Automation and Automobile Engineering
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Fig. 16: Assembled Model.

PERFORMANCE ANALYSIS with the lifting time for various load

After completion of the assembly of the conditions.
model, it is essential to perform the
performance test upon the model .the Load vs Lifting Time
performance test of model indicate the Performance of model under different load
how it performs under various conditions. conditions are as follows,
Here we are test the performance of model

Table 2: Load vs Lifting Time.

Sl. Load in Lifting time for full stroke (T1) in Lifting time for from the earth surface (T2) in
No kg Seconds. Seconds.
1 0 0.80 0.60
2 15 0.88 0.67
3 30 0.98 0.78
4 45 1.12 0.90
5 60 1.22 1.01
6 75 1.31 1.11
7 90 1.52 1.30

As we absorbing the valves in the Table 2 60mm in this stroke length 40mm not
the time taken for lifting load increasing affected by load and the stroke length
with increasing the load. The above valves from earth surface is only 20mm this
taken with reference of full stroke length is stroke length is affected by applied load

Load in kg
Load vs Lifting time
2
Lifting time in sec

1.5
Lifting time for full
1 stroke (T1)

0.5
Lifting time for from
the earth surface (T2)
0
15 30 45 60 75 90

Fig. 16: Graph Load vs Lifting Time.

We get the relationship between the load relationship, from which we can conclude
and lifting time. It has the linear that the lifting time increases with

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 Recent Trends in Automation and Automobile Engineering
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increasing load as shown in Figure 16. Khan, S., & Agarwal, S. (2013).
Inbuilt Hydraulic jack in Automobile
CONCLUSION vehicles. International Journal of
The developed inbuilt hydraulic jack for Innovations in Engineering and
four wheelers will help the ladies and old Technology, 2 (2), 76-84.
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source instead we can go with the rotating Photoplethysmogram at various sites.
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long run to the driver by simplifying his & Shriram, R. (2015). NIRS Based
job during the time of puncture and PPG Sensor for Detection of Oxy–Hb
breakdown. and Deoxy-Hb Change During
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