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Fabrication of remote controlled electro hydraulic jack with

surface sensor

A PROJECT REPORT

Submitted in partial fulfillment for the award of the degree of

B.TECH

In

Mechanical Engineering

by

VIVEK MADHUGIRI JAYAKUMAR - 12BME0612

School of Mechanical Engineering

MAY & 2017

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DECLARATION BY THE CANDIDATE

I hereby declare that the project report entitled “Fabrication of remote controlled
electro hydraulic jack with surface sensor” submitted by me to Vellore Institute of
Technology University, Vellore in partial fulfillment of the requirement for the
award of the degree of Bachelor in technology in Mechanical is a record of
bonafide project work carried out by me under the supervision of Sir
Senthilnathan N. I declare that this report represents my concepts written in my
own words and where others' ideas or words have been included, I have
adequately cited and referenced the original sources. I further declare that I have
adhered to all principles of academic honesty and integrity and have not
misrepresented or fabricated or falsified any idea/data/fact/source in my
submission. I understand that any violation of the above will be cause for
disciplinary action by the Institute and can also evoke penal action from the
sources which have thus not been properly cited or from whom proper permission
has not been taken when needed. Further I affirm that the contents of this report
have not been submitted and will not be submitted either in part or in full, for the
award of any other degree or diploma and the same is certified

Place : Vellore Signature of the Candidate

Date: 27/4/201
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School of Mechanical Engineering

BONAFIDE CERTIFICATE

This is to certify that the project report entitled “Fabrication of remote controlled
electro hydraulic jack with surface sensor” submitted by VIVEK MADHUGIRI
JAYAKUMAR to Vellore Institute of Technology University, Vellore, in partial
fulfillment of the requirement for the award of the degree of in is a record of bona
fide work carried out by him/her under my guidance. The project fulfills the
requirements as per the regulations of this institute and in my opinion meets the
necessary standards for submission. The contents of this report have not been
submitted and will not be submitted either in part or in full, for the award of any
other degree or diploma and the same is certified.

Project Coordinator Project Supervisor

Head of the Department External Examiner

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Acknowledgement

I would like to use this opportunity to thank my guide Sir Senthilnathan N for
providing me with his constant guidance and support. Sir gave me valuable
feedback at each stage of projects progress. I would also like to thank my faculties
who teached me the basics of design and fabrication as a part of my curriculum.
That helped me understand the project even more. I am very grateful to my guide
for guiding me in my completion of work .

Signature

Place: Vellore VIVEK MJ

Date: 27/4/2017
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TABLE OF CONENTS
Chapter no. TITLE Page number
EXECUTIVE SUMMARY VII
LIST OF TABLES IX
LIST OF FIGURES X

LIST OF SYMBOLS AND ABBREVIATIONS XI

1 1.INTRODUCTION TO TOPIC 1

1.1 LITERATURE REVIEW 2

1.2 LITERATURE GAP 3

1.3 MOTIVATION 4

1.4 OBJECTIVES 4

2 METHODOLOGY AND EXPERIMENTAL WORK 5

2.1 TECHNICAL SPECIFICATIONS 5

2.2 PROJECT EXECUTION STAGES 5

2.3 DESIGN APPROACH DETAILS 7

2.4 REALISTIC AND DESIGN CONSTRAINTS ADR. 26

2.5 CODE AND STANDARDS 26

3 RESULTS AND DISCUSSION 27

3.1 PARAMETERS UNDER STUDY AND PERFORMANCE METRICS 27

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4 CONCLUSION 30

4.1 CONTRIBUTIONS TO LITERATURE 30

4.2 SCOPE FOR FUTURE WORK 30

5 REFERENCES 31

6 PUBLICATIONS 32
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EXECUTIVE SUMMARY

The remote controlled Hydraulic jack is a modified form of conventional Hydraulic jack that
helps to lift the load using motor as a source of energy and gear. In this project we aim for the
following:
1.Controlling the jack remotely
2.To design & construct a 5Amp dc power supply to run the project assembly.

With the aid of technology, preference is now being given to luxury, comfort and safety. This
Mechanical Engineering Final Year project “Electrically Operated Hydraulic Jack” works on
the principle of converting rotational motion of motor into the linear vertical motion of
hydraulic jack machine.
Power is available all the time hence it can be withdrawn instantly and safely in a car. Alternate
power can be used. . This project can be used in a wide array of engineering applications.
The electro hydraulic jack has many additional benefits other than just lifting a heavy load. The
jack is controlled with an Infrared remote which can be used to control the jack from a distance
instead of bending down on your knees when using a usual scissor jack. It can be very useful in
operation for old people.
The other benefit being the IR sensor which can be used to identify if the jack is in safe lifting
vertical distance from the object. This can be used to save time and energy. The main work of
the project is to make the base plate. The base plate sounds simple but many holes needed to be
made to act as ducts for the hydraulic fluid. Since we need to seal the duct from air, I had to use
hex bolts to seal off the base plate from the atmosphere. Another part was changing the DC
motor shaft to attach spur gear wheels. The gears were attached onto the shaft. Also
understanding the various parts of the hydraulic cylinder was also interesting.
There were circuit boards used to operate the jack since it is electrically operated. So I had to
use the buffer and driver circuit, IR circuit and also the IR sensor which helps in the operation
of the 12V dc motor.

The objective of the jack was to reduce its size and make it as portable as possible. So this was
possible as the base plate small size fit all the components of the hydraulic jack. The jack as
calculated was supposed to lift approx. 2tonnes however it was found to lift only 1.5tonnes.
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This was mainly due to the small motor capacity which was used to make the jack less in
weight and more portable. This also caused the jack to lift its cylinder head more slowly.

However even after all these shortcomings the jack did its operation smoothly and successfully
and was found to lift a total of 1.5tonnes. so small cars, small SUV and hatchbacks can be lifted
by this jack.
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LIST OF TABLES

Table no. Title Page no.

1. Load applied(kg) vs. time taken for full lift(s) 21

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LIST OF FIGURES

Figure no. Title Page no.

1.1 Base plate 20

1.2 Motor clamp 20
1.3 Gear pump front 21
1.4 Hydraulic cylinder 21
1.5 Oil tank 22
1.6 Motor case 22
1.7 Screw for cylinder 23
1.8 Screw for tank 24
1.9 Screw for motor clamp 25

2.0 Electro Hydraulic jack final product 29

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LIST OF SYMBOLS AND ABBREVIATIONS

A.C Alternating current

AISI American iron and steel institute

a Ampere

A Area

a Centre distance

ASME American society of mechanical engineers

b Face width

cm Centimeter

D Diamteer

D.c Direct current

Dn Diode

DIL Dual in line

F Force

IC Integrated circuit

ICI Special integrated circuit

IR Infrared

ISI Indian standards institute

ISO International standards organization

K Stress concentration factor

Kbl Bending life factor

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Kd Design contact stress

Kg Kilograms

LED Light emitting diode

M module

M meter

mA mili ampere

Mm,mm2 milimetre, milimetre square

[Mt] Initial design torque

N Newton

N/O valve normally open

P Pressure

R Resistor

RC Resistance capacitance

RL Resistor inductor

S1 Switch

SAE Society of automotive engineers

T Torque

TR1 circuit Translator

T Transmitter

V Voltage

W Watt

Y form factor
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Z1 No. of teeth on pinion

Z2 No. of teeth on gear

ɸ Pressure angle

∏ Pi(3.14)