DESIGN AND FABRICATION OF MOTORIZED SCREW JACK

A PROJECT REPORT

Submitted by

ILAVAENIL M 8115U22ME014
JEBY DANIEL ROY R 8115U22ME018
NAVEENKUMAR T 8115U22ME036
SUNDHARAMOORTHY R 8115U22ME056

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
In

MECHANICAL ENGINEERING

K. RAMAKRISHNAN COLLEGE OF
ENGINEERING
(AUTONOMOUS)
SAMAYAPURAM, TRICHY – 621 112

ANNAUNIVERSITY
CHENNAI - 600 025

JUNE 2025
DESIGN AND FABRICATION OF MOTORIZED SCREW JACK

A PROJECT REPORT

Submitted by

ILAVAENIL M 8115U22ME014
JEBY DANIEL ROY R 8115U22ME018
NAVEENKUMAR T 8115U22ME036
SUNDHARAMOORTHY R 8115U22ME056

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
In

MECHANICAL ENGINEERING

K. RAMAKRISHNAN COLLEGE OF
ENGINEERING
(AUTONOMOUS)
SAMAYAPURAM, TRICHY – 621 112

ANNAUNIVERSITY
CHENNAI - 600 025

JUNE 2025

i
 K. RAMAKRISHNAN COLLEGE OF ENGINEERING
(AUTONOMOUS)
UNDER
ANNA UNIVERSITY, CHENNAI

BONAFIDE CERTIFICATE

This is to certify that the dissertation entitled “DESIGN AND FABRICATION OF

MOTORIZED SCREW JACK” is a Bonafide work carried out by Mr. ILAVAENIL M
Reg. No 8115U22ME014, Mr. JEBY DANIEL ROY R Reg. No 8115U22ME018, Mr.
NAVEENKUMAR T Reg No 8115U22ME036, Mr. SUNDHARAMOORTHY R
Reg No 8115U22ME056, under our direct supervision.

SIGNATURE SIGNATURE
Dr. H. RAMAKRISHNAN, M.E, Ph. D Mr. P.C. SANTHOSHKUMAR, M.E
HEAD OF THE DEPARTMENT, SUPERVISOR,
ASSOCIATE PROFESSOR, ASSISTANT PROFESSOR,
Mechanical Engineering Department, Mechanical Engineering Department,
K. Ramakrishnan College of Engineering, K. Ramakrishnan College of Engineering,
Tiruchirappalli - 621 112. Tiruchirappalli - 621 112.

SIGNATURE OF INTERNAL SIGNATURE OF EXTERNAL

EXAMINER EXAMINER

NAME: NAME:

DATE: DATE:
ii
 K. RAMAKRISHNAN COLLEGE OF ENGINEERING
(AUTONOMOUS)
UNDER
ANNA UNIVERSITY, CHENNAI

DECLARATION BY THE CANDIDATES

We declare that to the best of our knowledge the work reported here in
has been composed solely by ourself and that it has not been in whole or in part in
any previous application for a degree.

Submitted for the project Viva- Voce held at K. Ramakrishnan College of

Engineering on

SIGNATURE OF THE CANDIDATES

iii
 ACKNOWLEDGEMENT

We thank the Almighty God without his blessings it would not have been possible for
us to complete our project. At this pleasing moment of having successfully completed
our project, we wish to convey our sincere thanks and gratitude our management of
our college and our beloved chairman Dr. K. RAMAKRISHNAN, B.E, who provided
all the facilities to us.

We would like to express our sincere thanks to our Executive Director Dr. S.
KUPPUSAMY, M.B.A., Ph.D., for forwarding us to do our project and offering
adequate motivation in completing our project.
We are also grateful to our Principal Dr. D. SRINIVASAN, M.E., Ph.D., for his
constructive suggestions and encouragement during our project.
We wish to express our profound thanks to Dr. H. RAMAKRISHNAN, M.E., Ph.D,
Head of the Mechanical Engineering Department, for providing all necessary facilities
for doing this project. We wholeheartedly and sincerely acknowledge our deep sense of
gratitude and indebtedness to our beloved guide Mr. PC. SANTHOSHKUMAR,
M.E., Asst. Professor, Mechanical Engineering Department, for his expert guidance
and encouragement throughout the duration of the project.
We extend our gratitude to all the faculty members of the Mechanical Engineering
Department, K. RAMAKRISHNAN COLLEGE OF ENGINEERING, for their kind
help and valuable support to complete the project successfully. We would like to thank
our parents and friends who have always been a constant source of support in our
project.

iv
 K. RAMAKRISHNAN COLLEGE OF ENGINEERING
(AUTONOMOUS)
(Approved by AICTE & Affiliated to Anna University) Tiruchirappalli - 621 112
Accredited by NAAC with ‘A’ Grade – ISO 9001:2015 Certified Institution

VISION OF THE INSTITUTION

“To achieve a prominent position among the top technical institutions”

MISSION OF THE INSTITUTION

❖ To bestow standard technical education par excellence through state-of-the-

art infrastructure, competent faculty and high ethical standards.

❖ To nurture research and entrepreneurial skills among the students in cutting

edge technologies.

❖ To provide education that can be used as a tool to transform the students.

v
 K. RAMAKRISHNAN COLLEGE OF ENGINEERING
(AUTONOMOUS)
(Approved by AICTE & Affiliated to Anna University) Tiruchirappalli - 621 112
Accredited by NAAC with ‘A’ Grade – ISO 9001:2015 Certified Institution

DEPARTMENT OF MECHANICAL ENGINEERING

VISION OF THE DEPARTMENT

❖ To provide eminent Mechanical Engineers to the society and industries

through quality technical education and research.

MISSION OF THE DEPARTMENT

❖ To impart quality professional education through state of the art

infrastructure and resources.

❖ To motivate students and faculty to undertake research and development

activities in the thrust areas of mechanical engineering.

❖ To carryout collaborative projects with industries and academics with

fullest potential.

vi
 K. RAMAKRISHNAN COLLEGE OF ENGINEERING
(AUTONOMOUS)
(Approved by AICTE & Affiliated to Anna University) Tiruchirappalli - 621 112
Accredited by NAAC with ‘A’ Grade – ISO 9001:2015 Certified Institution

PROGRAM EDUCATIONAL OBJECTIVES ( PEOs)

PEO 1: Have Successful careers in industries or opt for higher studies and research.

PEO 2: Analyze, synthesize and design mechanical and allied products addressing

PEO 3: Exhibit technical expertise, communication skills, teamwork with

professionalism with ethical values.

PROGRAM SPECIFIC OUTCOMES (PSOs)

PSO1: Identify, formulate and solve engineering problems in three core streams of
Mechanical Engineering, i.e., design engineering, thermal and fluids engineering and
manufacturing engineering

PSO2: Design, develop, test and implement energy efficient systems for required
engineering applications.

vii
 K. RAMAKRISHNAN COLLEGE OF ENGINEERING
(AUTONOMOUS)
(Approved by AICTE & Affiliated to Anna University) Tiruchirappalli - 621 112
Accredited by NAAC with ‘A’ Grade – ISO 9001:2015 Certified Institution

PROGRAM OUTCOMES (PO’s)

1. Engineering knowledge: Apply the knowledge of mathematics, science,

engineering fundamentals, and an engineering specialization to the solution of
complex engineering problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze
complex engineering problems reaching substantiated conclusions using first
principles of mathematics, natural sciences, and engineering sciences.

3. Design/development of solutions: Design solutions for complex engineering

problems and design system components or processes that meet the specified needs
with appropriate consideration for the public health and safety, and the cultural,
societal, and environmental considerations

4. Conduct investigations of complex problems: Use research-based knowledge and

research methods including design of experiments, analysis and interpretation of
data, and synthesis of the information to provide valid conclusions.

5. Modern tool usage: Create, select, and apply appropriate techniques, resources,
and modern engineering and IT tools including prediction and modeling to complex
engineering activities with an understanding of the limitations.

viii
 K. RAMAKRISHNAN COLLEGE OF ENGINEERING
(AUTONOMOUS)
(Approved by AICTE & Affiliated to Anna University) Tiruchirappalli - 621 112
Accredited by NAAC with ‘A’ Grade – ISO 9001:2015 Certified Institution

6. The engineer and society: Apply reasoning informed by the contextual knowledge
to assess societal, health, safety, legal and cultural issues and the consequent
responsibilities relevant to the professional engineering practice.

7. Environment and sustainability: Understand the impact of the professional

engineering solutions in societal and environmental contexts, and demonstrate the
knowledge of, and need for sustainable development

8. Ethics: Apply ethical principles and commit to professional ethics and

responsibilities and norms of the engineering practice.

9. Individual and team work: Function effectively as an individual, and as a member

or leader in diverse teams, and in multidisciplinary settings

10. Communication: Communicate effectively on complex engineering activities with

the engineering community and with society at large, such as, being able to
comprehend and write effective reports and design documentation, make effective
presentations, and give and receive clear instructions.

ix
 K. RAMAKRISHNAN COLLEGE OF ENGINEERING
(AUTONOMOUS)
(Approved by AICTE & Affiliated to Anna University) Tiruchirappalli - 621 112
Accredited by NAAC with ‘A’ Grade – ISO 9001:2015 Certified Institution

11. Project management and finance: Demonstrate knowledge and understanding of

the engineering and management principles and apply these to one’s own work, as a
member and leader in a team, to manage projects and in multidisciplinary
environments.

12. Life-long learning: Recognize the need for, and have the preparation and ability to
engage in independent and life-long learning in the broadest context of
technological change.

x
 ABSTRACT

The conventional screw jack, commonly used for lifting vehicles and heavy loads,
often demands significant manual effort and time. This project focuses on the design
and fabrication of a motorized screw jack, aimed at reducing human effort, improving
safety, and enhancing efficiency in lifting operations. The system combines the
mechanical advantage of a lead screw with the automation provided by a DC electric
motor. The primary objective is to develop a compact, portable, and reliable lifting
mechanism that can be used in automotive workshops, garages, and roadside
emergency situations.

The mechanism works by converting the rotary motion of the motor into linear motion
to lift or lower the load. A gear reduction system is incorporated to ensure that the
motor provides sufficient torque to lift heavy objects without overheating or stalling.
The screw jack is fabricated using durable materials capable of withstanding high stress
and load conditions. The frame is designed for structural stability, while the screw and
nut are precision-machined for smooth operation. The motor is powered by a 12V DC
supply and controlled via a simple toggle switch, enabling the user to control the
direction of movement.

Incorporating safety features such as limit switches helps prevent over-extension or

over- retraction of the screw, minimizing the risk of mechanical failure or user injury.
The project involved detailed mechanical calculations to determine load-bearing
capacity, torque requirements, and material strength, ensuring that the final product is
both safe and efficient. Testing of the prototype confirmed that the motorized screw
jack could lift a typical car segment with ease, demonstrating its practical utility. This
project successfully integrates mechanical design with electrical control to create a
functional, user-friendly lifting device. It highlights the potential of automation in
traditional mechanical tools and lays the foundation for further development in
portable lifting technologies
xi
 TABLE OF CONTENTS

S.NO TITLE PAGE NO

1 Abstract XI
2 List Of Contents XIII
3 List Of Tables XIV
4 List Of Figures XV
5 List Of Symbols XVI

xii
 LIST OF CONTENTS

CHAPTER NO TITLE PAGE NO

1 Introduction 1
2 Literature survey 3
3 Description of equipment 5
3.1 Dc Motor 5
3.2 Starter 8
3.3 Rotor 9
3.4 Electromagnetic 10
3.5 Scissor jack 10
3.6 Battery 11
4 Design and drawing 13
4.1 Dc motor Specification 13
4.2 General machine Specifications 14
4.3 Design calculation 15
5 Fabrication 22
6 Working principle 23
7 Merits 24
8 Applications 25
9 List of materials 26
10 Cost Estimation 29
11 Conclusion 31
12 Photography 33

xiii
 LIST OF TABLES

TABLE NO. DESCRIPTION PAGE NO

1 Specifications of Motor 13

2 List of Materials Used 28

3 Cost Estimation Table 29

xiv
 LIST OF FIGURES

FIGURE TITLE PAGE

NUMBER NO

1 Battery circuit diagram 11

2 Clamp plate 17
3 Scissor jack 17
4 Base 18
5 Motor 18
6 Overall diagram 19

xv
 LIST OF SYMBOLS

Ø = Dia of the screw (mm)

L = Length of the base (mm)
W = Width of the base (mm)
P = Pitch of the screw thread (mm)
DPDT = Double Pole Double Throw switch

xvi
 CHAPTER – I

INTRODUCTION

A jackscrew is a type of jack which is operated by turning a lead screw. It is also known
as a screw jack and is commonly used as car jacks. A jackscrew's compressive force is
obtained through the tension force applied by its lead screw.

An Acme thread is most often used, as this thread is very strong and can resist the large
loads imposed on most jackscrews while not being dramatically weakened by wear over
many rotations.

These types are self-locking, which makes them intrinsically safer than other jack
technologies like hydraulic actuators which require continual pressure to remain in a
locked position. Most jackscrews are lubricated with grease.

Advanced screw mechanisms may use a recalculating-ball nut to minimize friction and
prolong the life of the screw threads, but such jackscrews are usually not self-locking.
The thread profile of such screws is semicircular, not trapezoidal as in an Acme thread.

Motorized Screw Jack has been conceived having studied the difficulty in lifting the any
type of light vehicles. Our survey in regard in several automobile garages revealed the
fact that mostly some difficult methods were adopted in lifting the vehicles for
reconditioning. Now the project has mainly concentrated on this difficulty, and hence a
suitable device has been designed.

1
Such that the vehicle can be lifted from the floor land without application of any
impact force. The fabrication part of it has been considered with almost case for its
simplicity and economy, such that this can be accommodated as one of the essential
tools on automobile garages.

This device the motorized screw jack for automobile garages has been developed
to later the needs of small and medium automobile garages, who are normally man
powered with very minimum of skilled labours. In most of the garages the vehicles
are lifted by using hand operated screw jack.

This needs high man power and skilled labours. In order to avoid all such
disadvantages. This, motorized screw jack has been designed in such a way that it
can be used to lift the vehicle very smoothly without any impact force. The
operation is made be simple that even an unskilled labour can handle, by just
demonstrating the working of the motorized screw jack once.

2
 CHAPTER – II
LITERATURE SURVEY

SCREW JACK:

When we are traveling in the road for a particular work, if suppose tyre get puncture
it will be a big headache to remove the tyre and fixing up the stepney also it is not
easy to lift the jack manually in the workshop. This makes the worker to get tired.
It’s all a tedious work for the worker. In order to overcome this problem we have
designed and developed a system called motorized jack operating through keypad
by having full control of the jack, we can easily lift it up and down by using the
on/off. This helps to reduce the burden of the worker.

A jackscrew's compressive force is obtained through the tension force applied by

its lead screw. An Acme thread is most often used, as this thread is very strong and
can resist the large loads imposed on most jackscrews while not being dramatically
weakened by wear over many rotations. These types are self-locking, which makes
them more intrinsically safe than other jack technologies like hydraulic actuators
which require continual pressure to remain in a locked position. Most jackscrews
are lubricated with grease.

Advanced screw mechanisms may use a recirculation-ball nut to minimize friction

and prolong the life of the screw threads, but such jackscrews are usually not self-
locking. The thread profile of such screws is semicircular, not trapezoidal as in an
Acme thread.

3
TYPES OF THREADS:

• British standard Whitworth (B.S.W) thread

• British association (B.A) thread
• American national standard thread
• Unified standard thread
• Square thread
• Acme thread
• Knuckle thread
• Buttress thread
• Metric thread

ULTIMATE AIM
The motorized power jack can be widely used in low-cost automation in
manufacturing industries. The weight lifting is quick and effortless, which reduces
the physical fatigue (tiredness) felt by the worker.

4
 CHAPTER-III

DESCRIPTION OF EQUIPMENT

3.1 D.C MOTOR:

The dc generators and d c motors have the same general construction.

MOTOR PRINCIPLE:

An electric motor is a machine which converts a electrical energy to mechanical energy.

All DC machines have five principal components viz (i) Field system (ii) armature core
(iii) armature winding (iv) Commutator (v) brushes

(i) Field system:

The function of the field system is to produce Uniform field within which the armature
rotates.it consists of a number of salient poles (of course, even number) bolted to the

inside of circular frame (generally called yoke) the yoke is usually made of solid cast
steel whereas the pole piece are composed of stacked laminations. Field coils are
mounted on the poles and carry the dc exciting current. The field coils are connected in
such a way that adjacent poles have opposite polarity.

The developed by the coils produces a magnetic flux that passes through the pole
pieces, the air gap, the armature and the frame. Practical dc machines have air gaps
ranging from 0.5mm to 1.5 mm. Since armature and field systems are composed of
materials that have permeability, most of the field coils is required to set up flux in the
5
air gap. By reducing the length of air gap, we can reduce the size of field coils (number
of turns).

(ii) Armature core:

The armature core is keyed to the machine shaft and rotates between the field poles. It
consists of slotted soft-iron laminations (about 0.4 to 0.6mm thick) that are stacked to
form a cylindrical core. The laminations are individually coated with a thin insulating
film so that they do not come in electrical contact with each other.

The purpose of laminating the core is to reduce the eddy current loss. The laminations are
slotted to accommodate and provide mechanical security to the armature winding and to
give shorter air gap for the flux to cross between the pole face and the armature “teeth”.

(iii) Armature winding:

The slots of the armature core hold conductors that are connected in a suitable manner.
this are known as armature winding. This is the winding in which “working” emf is
induced.
The armature conductors are connected in series-parallel: the conductors being connected
in series so as to increase the voltage and in parallel paths so as to increase the current.
the armature winding of a dc machine is a closed –circuit winding: the conductors being
connected in a symmetrical manner forming a closed loop or series of closed loops.

(i) commutator;

A commutator is a mechanical rectifier which converts the alternating voltage generated

in the armature winding into direct voltage across the brushes. the commutator is made
of copper segments insulated from each other by mica sheets and mounted on the shaft of
the machine. The armature conductors are soldered to the commutator segments in a
6
suitable manner to give rise to the armature winding depending upon the manner in which
the armature conductors are connected to the commutator segments, there are two types
of armature winding in a dc machine viz(a) lap winding (b) wave winding.
Great care is taken in building the commutator because any eccentricity will cause the
brushes to bounce, producing unacceptable sparking. the sparks may burn the brushes and
overheat and carbonize the commutator.

(ii) Brushes:

The purpose of brushes is to ensure electrical connections between the rotating

commutator and stationary external load circuit. The brushes are made of carbon and rest
on the commutator, the brush pressure is adjusted by means of adjustable springs the
brush pressure is Very large, the friction produces heating of the commutator and the
brushes. on the other hand, if it is too weak, the imperfect contact with the commutator
may produce sparking.

3.2 STATOR:

The stator is the stationary part of an electric generator or electric motor. The non-
stationary part on an electric motor is the rotor.
Depending on the configuration of a spinning electromotive device the stator may act as
the field magnet, interacting with the armature to create motion, or it may act as the
armature, receiving its influence from moving field coils on the rotor.
The first DC generators (known as dynamos) and DC motors put the field coils on the
stator, and the power generation or motive reaction coils are on the rotor. This was

necessary because a continuously moving power switch known as the commutator is

needed to keep the field correctly aligned across the spinning rotor. The commutator must
become larger and more robust as the current increases.

7
The stator of these devices may be either a permanent magnet or an electromagnet. Where
the stator is an electromagnet, the coil which energizes it is known as the field coil or field
winding.

3.3 ROTOR:

The rotor is a fundamental component in various mechanical and electrical systems, playing
a crucial role in converting different forms of energy into rotational motion. In electric motors
and generators, the rotor is the rotating part of the machine and is typically mounted on a shaft
supported by bearings. It interacts with the stator, the stationary component, to either produce
motion (in motors) or generate electricity (in generators) through electromagnetic induction.

The rotor can be designed in different forms, such as squirrel cage or wound type, depending
on the application and performance requirements. In turbines, such as steam or gas turbines,
the rotor consists of a shaft with blades or vanes that spin when struck by fluid or gas,
transforming thermal or pressure energy into mechanical work. Similarly, in helicopters and
wind turbines, the rotor includes large blades that rotate to produce lift or electricity. The
design of a rotor is highly specialized and depends on the required speed, torque, and
environmental conditions.

Key considerations in rotor design include balance, weight distribution, material strength,
and heat dissipation. Advanced rotors are often made from high-strength materials such as
composites, aluminum, or steel to ensure durability and efficiency. In high-speed
applications, rotors must be precisely balanced to avoid vibrations that can cause damage or
reduce performance.

8
The efficiency of a system largely depends on the rotor's performance, making it a critical
focus in engineering and design. Whether used in industrial machines, transportation, energy
production, or household appliances, the rotor serves as a vital part of the mechanism,
converting energy and enabling motion that powers modern technology.

ELECTROMAGNETIC COIL:

An electromagnetic coil is formed when a conductor solid copper wire is wound around
a core or form to create an inductor or electromagnet. One loop of wire is usually referred
to as a turn, and a coil consists of one or more turns. For use in an electronic circuit,
electrical connection terminals called taps are often connected to a coil. Coils are often
coated with varnish and/or wrapped with insulating tape to provide additional insulation
and secure them in place. A completed coil assembly with taps etc. is often called a
winding. A transformer is an electromagnetic device that has a primary winding and a
secondary winding that transfer’s energy from one electrical circuit to another by
magnetic coupling without moving parts. The term tickler coil usually refers to a third
coil placed in relation to a primary coil and secondary coil. A coil tap is a wiring feature
found on some electrical transformers, inductors and coil pickups, all of which are sets of
wire coils. The coil tap is in a wire coil where a conductive patch has been exposed. As
self-induction is larger for larger coil diameter the current in a thick wire tries to flow on
the inside. The ideal use of copper is achieved by foils. Sometimes this means that a spiral
is a better alternative. Multilayer coils have the problem of interlayer capacitance, so
when multiple layers are needed the shape needs to be radically changed to a short coil
with many layers so that the voltage between consecutive layers is smaller.

3.4 SCISSOR JACK:

Here we are using the jack name “scissor” to work under the car to change wheels, it is
necessary to lift the car for doing this a lifting jack is used which may be mechanically or

9
hydraulically operated. Such a jack is a standard accessory with many cars. It consists of
a diamond shaped frame having a nut and on one side and a sleeve on the other side. A
screw is supported in the nut and the sleeve. Rotating the screw with a handle moves the
nut towards or away from the sleeve depending upon the direction of the rotation, so that
the vehicle supported on the jack is lifted or moved down. The jack
is so designed that there is always sufficient friction in the screw to hold the jack from
moving down under load. But we are using the motor to rotate the screw for lifting the
vehicle.

PARTS OF A JACK
SHAFT:
It’s made up of mild steel. It is straight rod having a step on the one shaft. The
shaft is placing for the motor arrangement and for rotates the gear. The diameter of rod is
8mm for a length of 70mm.

SUPPORTING PLATE:

The plate is made up of mild steel plate which is placing below the belt. It is for
to transmit the object to straight bath. It does not affect the belt to be of rest.

3.5 BATTERY:

Battery is use for storing the energy produced from the solar power. The battery used is a
lead-acid type and has a capacity of 12v; 2.5A.the most inexpensive secondary cell is the
lead acid cell and is widely used for commercial purposes. A lead acid cell when ready
for use contains two plates immersed in a dilute sulphonic acid (H2SO4) of specific gravity
about 1.28.the positive plate (anode) is of Lead –peroxide (PbO2) which has chocolate
brown color and the negative plate (cathode) is lead (Pb) which is of grey color.

10
When the cell supplies current to a load (discharging), the chemical action that takes
place forms lead sulphate (PbSO4) on both the plates with water being formed in the
electrolyte. After a certain amount of energy has been withdrawn from the cell, both plates
are transformed into the same material and the specific gravity of the electrolyte (H 2so4)
is howardite cell is then said to be discharged. There are several methods to ascertain
whether the cell is discharged or not.

To charge the cell, direct current is passed through the cell in the reverse direction
to that in which the cell provided current. This reverses the chemical process and again
forms a lead peroxide (PbO2) positive plate and a pure lead (Pb) negative plate. At the
same time, (H2so4) is formed at the expense of water, restoring the electrolyte (H2so4 ) to
its original condition. The chemical changes that
Occur during discharging and recharging of a lead-acid cell.

BATTERY CIRCUIT DIAGRAM:

FIGURE NO: 1 BATTERY CIRCUIT DIAGRAM

11
CIRCUIT DIAGRAM DETAILS:

In our project we are using a secondary type battery. It is rechargeable Type. A battery is
one or more electrochemical cells, which store chemical energy and make it available as
electric current. There are two types of batteries, primary (disposable) and secondary
(rechargeable), both of which convert chemical energy to electrical energy. Primary
batteries can only be used once because they use up their chemicals in an irreversible
reaction. Secondary batteries can be recharged because the chemical reactions they us
are reversible; they are recharged by running a charging current through the battery, but
in the opposite direction of the discharge current. Secondary, also called rechargeable
batteries can be charged and discharged many times before wearing out. After wearing
out some batteries can be recycled.

Batteries have gained popularity as they became portable and useful for many purposes.
The use of batteries has created many environmental concerns, such as toxic metal
pollution. A battery is a device that converts chemical energy directly to electrical energy
it consists of one or more voltaic cells. Each voltaic cell consists of two half cells
connected in series by a conductive electrolyte.

One half-cell is the positive electrode, and the other is the negative electrode. The
electrodes do not touch each other but are electrically connected by the electrolyte, which
can be either solid or liquid. A battery can be simply modeled as a perfect voltage source
which has its own resistance, the resulting voltage across the load depends on the ratio of
the battery's internal resistance to the resistance of the load.

When the battery is fresh, its internal resistance is low, so the voltage across the load is
almost equal to that of the battery's internal voltage source. As the battery runs down and

12
its internal resistance increases, the voltage drop across its internal resistance increases,
so the voltage at its terminals decreases, and the battery's ability to deliver power to the
load decreases.

4. DESIGN OF EQUIPMENT AND DRAWING

The motorized power jack machine consists of the following components to full fill the
requirements of complete operation of the machine.
➢ Dc motor

➢ Screw jack

➢ Battery

4.1 DC MOTOR SPECIFICATIONS:

MOTOR SPECIFICATION:

S.NO PARAMETER SPECIFICATIONS

1 Motor Type Permanent Magnet DC Motor (Wiper Motor)

2 Rated Voltage 12V DC

3 Rated Torque 10–15 Nm

4 Load current 5-7 A

5 Power Rating 30-50 Watts

6 Output Shaft Worm Gear Driven

7 Housing Material PBT-GF30 (Glass-Fiber Reinforced Plastic)

8 Mounting Type Side Mount with Bolt Holes

9 Application Automotive wipers, DIY Lift Systems

13
4.2 GENERAL MACHINE SPECIFICATIONS:

TECHNICAL DATA:
1. DC MOTOR

Voltage =12v DC
Rpm =30
Watts =18w

Length of the motor =170mm

Outer dia of motor =Ø 60mm

2. BASE OF JACK

Height of base =218 mm

Length of base =340mm

3. CLAMPER

Length of clamp =83mm

Width of clamp =70mm
Thickness of clamp =1mm

General unit

Size of machine (L x H) : 700mm*350mm

14
4.3 DESIGN CALCULATION

To find out the power of the motor that can lift load of 750kg

We know,

Major Screw dia (do) =12mm

Pitch of screw (p) = 3mm

Mean dia, d = do - p/2

= 12-3/2

d=10.5mm

tan∞ =p/ πd
tan∞=3/π x10.5
tan∞ =0.091

Assuming coefficient of friction, tanθ =0.1

Load to be raised =750 kg
W =7500N

P = effort required to raise the load

P = W X tan (∞+θ)

= W X (tan ∞+ tan θ)/ (1-tan∞Xtan θ)

= 7500 X (0.091 +0.1)/ (1-0.091X0.1)

=7500 X (0.191/0.99)
P =1440N

15
Torque required operating the screw.
T=P X d/2

T =1440 X10.5/2
T =7560 X10-3 Nm
Since the screw moves in the nut at a speed of 65mm/min of speed of revolutions is
minute is,
N =speed in mm/min/pitch in mm
N = 65/3(pitch)
=21.6 (22 rpm)

Power of the motors required,

P=TXω
Where ω is = 2 X π X N/60

P=TXω

P = 7560 X10-3 X 2 X π X 22/60

P = 17.41 watts

16
 DRAWING

FIGURE NO: 2 CLAMP PLATE

FIGURE NO: 3 SCISSOR JACK

17
 FIGURE NO: 4 BASE

FIGURE NO: 5 MOTOR

18
 MOTORIZED POWER JACK

FIGURE NO: 6 MOTORIZED SCREW JACK

19
TOP VIEW AND FRONT VIEW OF THE DESIGNED
MOTORIZED SCREW JACK

20
SIDE VIEW AND ISOMETRIC VIEW OF THE DESIGNED
MOTORIZED SCREW JACK

21
 CHAPTER-V
FABRICATION
METHOD OF FABRICATION:

The fabrication of the motorized screw jack involves a series of systematic

steps that integrate mechanical components with an electrical drive system. The process
begins with the design phase, where detailed drawings and CAD models are created to
determine the appropriate dimensions and fit of the components. Based on load
requirements and performance expectations, materials such as mild steel and alloy steel
are selected for their strength, durability, and machinability. The fabrication starts with
machining the lead screw and matching threaded nut, which form the core of the lifting
mechanism.

The lead screw is turned and threaded using a lathe machine to achieve the desired pitch
and thread accuracy, while the nut is fabricated to match the screw threads, ensuring
smooth engagement and minimal backlash. The base frame and support structure are then
cut from steel plates and welded to form a rigid and stable platform. Guide rails and
brackets are added to maintain alignment and minimize lateral movement during
operation. Once the mechanical structure is complete, a DC motor is selected based on
torque calculations, and a suitable gear reduction unit is coupled to the motor shaft to
enhance torque output while reducing speed.

The motor is mounted securely on the frame, and a coupling is used to connect it to the
lead screw. Electrical wiring is done to connect the motor to a 12V DC power source via
a DPDT (Double Pole Double Throw) switch, which allows the motor to rotate in both
directions—raising and lowering the jack. To enhance safety, limit switches are installed
at the upper and lower ends of the screw’s travel path to automatically cut off power when
the jack reaches its maximum or minimum position. After assembly, the entire unit is
tested for functionality, load capacity, and operational stability. Adjustments are made if
necessary to ensure smooth and reliable performance.
22
 CHAPTER-VI

WORKING PRINCIPLE

The motorized screw jack operates by integrating an electric DC motor with a traditional
mechanical scissor jack to automate the lifting process of heavy vehicles or loads. The
system is powered by a 12V DC battery, and its operation is controlled using a simple
ON/OFF switch. When the switch is turned ON, it sends a high signal to the control
circuit, which then activates a relay to rotate the DC motor in the forward direction. This
motor rotation drives the lead screw mechanism of the scissor jack, converting the motor’s
rotary motion into linear motion that lifts the load upwards.

Conversely, when the switch is turned OFF, the control circuit sends a low pulse,
triggering the relay to reverse the motor’s rotation. This causes the jack to descend,
bringing the load back down smoothly. The motorized mechanism eliminates the need for
manual cranking, significantly reducing physical effort and time required to lift or lower
the vehicle. The system is designed to ensure stability and safety during operation, with
adequate friction in the screw to hold the position without slipping. This simple yet
effective working principle demonstrates the practical application of electromechanical
integration in easing mechanical operations, making it highly useful for automobile
workshops and emergency roadside applications.

23
 CHAPTER-VII

MERITS

• Low cast.

• Easy to work and reduces the manual stress.

• Reduce the manpower.

• Small size

• Low power consumption

24
 CHAPTER-VIII

APPLICATIONS

• Used in automobile workshops and service stations for lifting vehicles during
maintenance and repairs.

• Ideal for roadside emergency situations to easily lift a vehicle without manual
effort.

• Can be included as part of the toolkit in passenger vehicles for quick and
convenient tire changes.

• Useful in small-scale industries for lifting and positioning heavy components or

assemblies.

• Applied in material handling tasks where controlled lifting is needed.

• Suitable for use in low-cost automation systems in various manufacturing

processes.

• Reduces physical strain, making it helpful for elderly or physically limited users

25
 CHAPTER-IX
LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed below.

1. Properties:

The material selected must posses the necessary properties for the proposed
application. The various requirements to be satisfied
Can be weight, surface finish, rigidity, ability to withstand environmental attack from
chemicals, service life, reliability etc.
The following four types of principle properties of materials decisively affect their
selection
a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific gravity, electrical

conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

Compressive shear, bending, torsional and buckling load, fatigue resistance, impact

26
resistance, elastic limit, endurance limit, and modulus of elasticity, hardness, wear resistance
and sliding properties.
The various properties concerned from the manufacturing point of view are,

➢ Cast ability

➢ Weld ability

➢ Surface properties

➢ Shrinkage

➢ Deep drawing etc.

2. Manufacturing case:

Sometimes the demand for lowest possible manufacturing cost or surface qualities
obtainable by the application of suitable coating substances may demand the use of special
materials.

3. Quality Required:

This generally affects the manufacturing process and ultimately the material. For
example, it would never be desirable to go casting of a less number of components which
can be fabricated much more economically by welding or hand forging the steel.

4. Availability of Material:

Some materials may be scarce or in short supply.it then becomes obligatory for the
designer to use some other material which though may not be a perfect substitute for the
material designed. The delivery of materials and the delivery date of product should also be
kept in mind.
27
5. Space consideration

Sometimes high strength materials have to be selected because the forces involved are
high and space limitations are there.

6. Cost:

As in any other problem, in selection of material the cost of material plays an

important part and should not be ignored.

Sometimes factors like scrap utilization, appearance, and non-maintenance of

designed part are involved in the selection of proper materials.

LIST OF MATERIALS USED:

S. NO DESCIRPTION QTY MATERIAL

1 Dc motor 1 Cast iron

2 Jack plate 4 Mild steel
3 Screw rod 1 Mild steel
4 Base 1 Mild steel

5 Battery 1 Electronic
6 DPDT Switch 1 Electronic
7 Angle plate 3 Mild steel
8 Supporting plate 1 Mild steel
9 Wire 3 Copper wire

28
 CHAPTER-X

COST ESTIMATION

1. MATERIAL COST:

S. No DESCIRPTION QTY MATERIAL AMOUNT

(Rs)
1 Dc motor 1 Cast iron 1250
2 Jack plate 4 Mild steel 150
3 Screw rod 1 Mild steel 400
4 Base 1 Mild steel 600
5 Battery 1 Electronic 900
6 DPDT Switch 1 Electronic 100
7 Angle plate 3 Mild steel 200
8 Supporting plate 1 Mild Steel 250
9 Wire 3 Copper wire 100
TOTAL 3950

2. LABOUR COST:

➢ Lathe

➢ Drilling

➢ Grinding

➢ Welding

29
 ➢ Power hacksaw

➢ Gas cutting cost

3. OVERHEAD CHARGES:

The overhead charges have arrived by “manufacturing cost”

Manufacturing Cost = Material Cost + labor Cost

= 3950 + 1000

= 4950 Rs.

Overhead Charges =20% of the manufacturing cost

= 984 Rs.

4. TOTAL COST:
Total cost = Material Cost +Labor Cost +Overhead Charges

= 3950 + 1000 + 984

= 5934 Rs.

Total cost for this project = 5934 Rs.

30
 CHAPTER-XI

CONCLUSION

The motorized screw jack project successfully demonstrates the integration of mechanical
and electrical systems to create a user-friendly, efficient, and reliable lifting device. By
replacing manual effort with an electric motor, the system significantly reduces the
physical strain and time involved in lifting heavy vehicles or machinery. The design is
compact, portable, and can be easily operated by individuals with minimal technical
knowledge, making it ideal for both professional automotive workshops and personal
vehicle use.

The project meets its objectives by enhancing safety, improving efficiency, and providing
a cost-effective alternative to manual or hydraulic jacks. The working model confirms that
the motorized jack can handle significant loads while maintaining operational stability and
safety. This project also reinforces important engineering principles such as load
calculation, torque transmission, material selection, and control circuit design. Overall, the
motorized screw jack offers a practical solution for lifting tasks and holds strong potential
for further development and commercial application.

31
 REFERENCES

1. Kirpal Singh (2011). Automobile Engineering – Vol. 1 & 2. Standard Publishers

Distributors.

2. Theraja, B.L., & Theraja, A.K. (2005). A Textbook of Electrical Technology

(Vol. I & II). S. Chand Publishing.

3. R.S. Khurmi & J.K. Gupta (2005). Theory of Machines. S. Chand & Company Ltd.

4. P.S.G. College of Technology (2000). Design Data Book. Kalaikathir Achchagam,

Coimbatore.

5. Bhandari, V.B. (2010). Design of Machine Elements (3rd ed.). Tata McGraw-Hill
Education.

6. Hajra Choudhury, S.K., Hajra Choudhury, A.K., & Nirjhar Roy, S.K. (2010).
Elements of Workshop Technology (Vol. I: Manufacturing Processes). Media
Promoters & Publishers Pvt. Ltd.

7. Bhatt, N.D. (2009). Engineering Drawing (53rd ed.). Charotar Publishing House.

8. Mahadevan, K., & Reddy, K. Balaveera (2013). Design Data Handbook for
Mechanical Engineers. CBS Publishers & Distributors Pvt. Ltd.

9. M. Hasek (1971). Manufacturing Technology. Mir Publishers.

32
PHOTOGRAPHY

33
34