FABRICATION OF MOTORIZED HYDRAULIC JACK

A PROJECT REPORT

Submitted by

ASLIN MERSHO M J

MANOJ M

ABILASH S

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING

MAR EPHRAEM COLLEGE OF ENGINEERING AND TECHNOLOGY

ELAVUVILAI, MARTHANDAM

ANNA UNIVERSITY : CHENNAI 600 025

MAY 2024
 ANNA UNIVERSITY: CHENNAI-600025

BONAFIDE CERTIFICATE

Certified that this project report “FABRICATION OF MOTORIZED

HYDRAULIC JACK” is the bonafide work of “ASLIN MERSHO M J
(961420114022), MANOJ M(961420114039),ABILASH S(961420114003)” who
carried out the project work under my supervision.

SIGNATURE SIGNATURE

Dr. D. RAJEEV., M.E, PhD. Dr. P. ANTO PAULIN MERINTO, M.E,PhD

HEAD OF THE DEPARTMENT SUPERVISOR

Department of Mechanical engineering Department of Mechanical Engineering

Mar Ephraem College of Engineering Mar Ephraem College of Engineering And
Technology, Elavuvilai, Marthandam, And Technology,Elavuvilai,Marthandam
Pin 629171 Pin 629171.

Submitted to the university viva-voce examination held at Mar Ephraem

College of Engineering and Technology on ………………….

INTERNAL EXAMINER EXTERNAL EXAMINER

 AGKNOWLEDGEMENT

First of all we would like to thank the Almighty God for showering
his blessings upon us. We express our sincere thanks to our correspondent Very
Rev. Fr. Sateesh Kumar for providing full facilities and technical environment
to start this project work. We express our heartfelt gratitude to our principal Dr.
A. Lenin Fred, M.E., Ph.D., of our institution for his constant support.

We can never forget the help rendered by our Director Dr. N. Austin, M.E.,
Ph.D., for the encouragement and moreover for their timely support and guidance
till the completion of our project work.

We are highly obliged to Prof. Dr. D. Rajeev, M.E., Ph.D. Head of the
Mechanical Engineering Department for rendering his full support both mentally
and technically by encouraging us at all times as needed.

We also express our honest and humble gratitude to Prof. Dr.

[Link] Pithalis,M.E., Ph.D. project coordinator and our project
supervisor for his valuable advice, constant encouragement, timely support and
guidance for finishing the project work successfully.

We would like to express our whole hearted thanks to our project supervisor,
Dr. S.L. Beschi Selvan,B.E, Ph.D. Assistant professor in mechanical engineering
department to meet all changes and come up with our project victory. Last but not
the least we thank all the Teaching and Non-Teaching staff members of
Mechanical Engineering Department and our friends for their sole help and Co-
operation in successful completion of this project. We would like to express very
much indebted to our beloved Parents and Friends for their love, support and
encouragement

i
 ABSTRACT

The Objective of the project work is to design and develop an automated

hydraulic jack system. A jack is a mechanical lifting device used to apply

greater force to lift heavy loads. A mechanical jack employs a screw thread for

lifting heavy equipment. A hydraulic jack uses hydraulic power. It is a tool that

raises and lowers the automotive vehicle. The automated hydraulic jack will be

useful to elderly people and women who find it extremely difficult to physically

operate the jack during any car breakdown. Whenever the tire failure was

occurred in the automotive vehicle, lifting the vehicle from ground surface is

very difficult, it also involves intense human effort and it is a more time taking

process. For rectifying, this kind of problem an automated hydraulic jack

system helps to lift the vehicle automatically from the ground instead of

conventional mechanical jack, which can save the time and excess effort. The

motive behind this work is use an automated jack system which can produce

more power and simpler in design as compared to a conventional design. When

compared to a pneumatic system, which runs on compressible air, hydraulic

systems have a greater lifting capacity since the hydraulic oil is incompressible.

ii
 CONTENTS

CHAPTER TITLE PAGE

NO NO
Abstract i
List of Figures iv
List of Tables v
List of Symbols and Abbreviations vi
1 Introduction 1
1.1 Need for Automation 2
2 Literature survey 3
2.1 Hydraulic system 3
2.2 Comparative advantages of hydraulic system 3
2.3 Familiarity of Hydraulic principles 4
3 Objective of the project 5
3.1 Hydraulic components and description 5
3.1.1 Multiple units 7
3.2 Types of hydraulic cylinder 7
3.2.1 Single Acting Hydraulic Cylinder 7
3.2.2 Double Acting Hydraulic Cylinder 8
3.2.3 The Reciprocating Pumps 9
4 Automated hydraulic jack components and description 11
4.1 Major components 11
4.1.1 Single acting hydraulic cylinder 11
4.1.2 Oil tank 11
[Link] Hydraulic fluids 11
4.1.3 Hydraulic pump with motor 12
4.1.4 Connectors 12
4.2 Relation between lifting force and piston pump force 13
4.3 Working principle 16
4.4 Methodology 16
5 Some of the factors affecting Automated hydraulic jack 18
5.1.1 Manufacturing case 18
iii
 5.1.2 Quality required 18
5.1.3 Availability of material 18
5.1.4 Space consideration 18
5.1.5 Cost 18
5.2 Generally used materials 19
5.3 Advantages and disadvantages 21
5.3.1 Advantage 21
5.3.2 Disadvantage 22
5.4 Applications 22
5.5 Types of cost occur during the project 23
5.5.1 Material Cost 23
5.5.2 Labour Cost 23
5.5.3 Overhead Charges 23
5.5.4 Total Cost 23
6 6.1 Summary 24
6.2 Conclusion 24
6.3 Reference 25

iv
 LIST OF FIGURES

FIGURE TITLE PAGE

NO
3.1 2D Model 5
3.2 Applied pressure is exerted equally in all directions 6
3.3 Transmission of equal pressures to equal area 7
3.4 Multiple units from a single source of power 7
3.5 Single acting hydraulic cylinder 8
3.6 Double acting hydraulic system 9
3.7 Hand-operated reciprocating pump 10
4.1 Simple Hydraulic Jack Model 12
4.2 Design Bending Moment diagram for hydraulic jack 14
4.3 Proposed Design of Automated Hydraulic Jack 15
4.4 Drafting Representation of Automated Hydraulic Jack 15

v
 LIST OF TABLES

TABLE TITLE PAGE

NO NO
2.1 Different Case factors of product efficiency 3
5.1 Cylinder Tube Materials: 19
5.2 End Cover Materials 19
5.3 Piston Materials 20
5.4 Mount Materials 20
5.5 Piston Rod Materials 21
5.6 List of Materials 22

vi
 LIST OF SYMBOLS AND ABBREVIATIONS

P Pressure Exerted by the

Cylinder
F Force of the Piston
A Cross Sectional Area
R Radius of Piston
π Mathematical Symbol
Σ Summation
L Length of the cylinder

vii
 CHAPTER-1

INTRODUCTION

The objective of the work is to replace design and develop an automated hydraulic jack
for lifting purpose in automotive vehicle. In hydraulic device, power is transmitted by pushing
the confined liquid. It is a mechanical function that operated through force or liquid pressure. It
is based on the principle of Pascal’s law. The application of hydraulic system is usually used in
various fields like food industry, beverage industry, machinery industry, automotive industry,
robotic arms, it can withstand and lift heavy loads.
Normally we use bottle hydraulic jack, scissor jack for lifting vehicles. The ground
clearance of a car should be considered mainly during this operation. In this system they have
replaced conventional hydraulic jack as inbuilt hydraulic jack and they have integrated in the
vehicle. Following studies can also analyses the advantages of an integrated hydraulic jack
system over a conventional mechanical jack system. By examining the design of the prototype,
it is possible to see that the design of the built-in hydraulic jacks and also automated hydraulic
jack is also investigated and adjusted to the necessary extent.
The built-in self-jacking component is started by pressing the designated button on the
dashboard. The built-in hydraulic jack will be helpful to elderly people and ladies who find it
extremely difficult to physically operate the jack during any car breakdown. This hydraulic jack
will have the ability to lift the wheels in accordance with our requirements; for example, if we
just need to lift two wheels, the cylinder will be moved as necessary on the rack with the help of
the DC motor.
Degrees of automation are of two types, viz.
Full automation.
Semi automation.
In semi automation a combination of manual effort and mechanical power is required where as in
full automation human participation is very negligible.

1
NEED FOR AUTOMATION:

Automation can be achieved through computers, hydraulics, pneumatics, robotics, etc.,

of these sources, pneumatics forms an attractive medium for low-cost automation. The main
advantages of all pneumatic systems are economy and simplicity. Automation plays an
important role in mass production. For mass production of the product, the machining
operations decide the sequence of machining. The machines designed for producing a
particular product are called transfer machines. The components must be moved automatically
from the bins to various machines sequentially and the final component can be placed
separately for packaging. Materials can also be repeatedly transferred from the moving
conveyors to the work place and vice versa. Nowadays almost all the manufacturing process
is being atomized in order to deliver the products at a faster rate. The manufacturing operation
is being atomized for the following reasons.

To achieve mass production

To reduce man power

To increase the efficiency of the plant

To reduce the work load

To reduce the production cost

To reduce the production time

To reduce the material handling

To reduce the fatigue of workers

To achieve good product quality

Less Maintenance

2
 CHAPTER-2

LITERATURE SURVEY

HYDRAULIC SYSTEM

In the development of the submarine from pre-war classes, many changes and
improvements have occurred. One of the outstanding differences is the large variety of
submarine devices which are now operated by hydraulic power. In early classes, there was no
hydraulic system, and power requirements were met by means of air or electricity. Along with
constantly improving submarine design has gone a constant extension and diversification of the
use of hydraulic power.

COMPARATIVE ADVANTAGES OF HYDRAULIC POWER

Hydraulic systems possess numerous advantages over other systems of power

operation. They are light in weight; they are simple and extremely reliable, requiring a
minimum of attention and maintenance. Hydraulic controls are sensitive, and afford precise
controllability. Because of the low inertia of moving parts, they start and stop in complete
obedience to the desires of the operator, and their operation is positive. Hydraulic systems are
self-lubricated; consequently, there is little wear or corrosion. Their operation is not apt to be
interrupted by salt spray or water. Finally, hydraulic units are relatively quiet in operation, an
important consideration when detection by the enemy must be prevented. Therefore, in spite of
the presence of the two power sources just described, hydraulic power makes its appearance
on the submarine because of the fact that its operational advantages, when weighed against the
disadvantages enumerated for electricity and air in the preceding paragraphs, fully justify the
addition of this third source of power to those available in the modern submarine.

3
 Table2.1 Different Case Factors of Product Efficiency

FACTOR AIR ELECTRICITY HYDRAULICS

Reliability Poor Good Good

Weight Light Heavy Light

Simple Simple Simple

Control Valves Switches and solenoids Valves

Mechanism
Maintenance Constant attention Difficult, requiring skilled Simple
necessary personnel
Vulnerability High pressure bottle Good Safe; broken lines cause
dangerous; broken lines cause failure
failure and danger to personnel
and equipment
Response Slow for both starting Rapid starting, slow Instant starting and
and stopping stopping stopping
Controllability Poor Fair Good

Quietness of Poor Poor Good

Operation

4
FAMILIARITY OF HYDRAULIC PRINCIPLES

For many centuries, man has utilized hydraulic principles to satisfy common, everyday needs,
opening a faucet to fill a sink with water a practical application of hydraulics. Water moves
through a dam in accordance with well-known principles of fluid motion. There are hydraulic
principles that explain the action of fluids in motion and others for fluids at rest. We are
chiefly concerned, however; with that branch of hydromechanics which is called simply
Hydraulics and is defined in engineering textbooks as the engineering application of fluid
mechanics. It includes the study of the behavior of enclosed liquids under pressure, and the
harnessing of the forces existing in fluids to do some practical tasks such as steering a
submarine or opening the outer door of a torpedo tube. Examples of hydraulically operated
equipment are familiar to all. Barber or dentist chairs are raised and lowered hydraulically; so
is an automobile when placed on a hydraulic rack for a grease job. Stepping on the brake pedal
in an automobile creates the hydraulic power which stops the rotation of the four wheels and
brings the car to a halt. For an understanding of how a hydraulic system works, we must know
the basic principles, or laws, of hydraulics, that is, of confined liquids under pressure.

5
 CHAPTER-3

OBJECTIVE OF THE PROJECT

 To integrate hydraulic jack system in four-wheeler vehicle.

 To lift the car in semi-automated way.

 To patch the punctured vehicle on any circumstances.

 To reduce man power.

 To access the system at any circumstances and easy to operate.

HYDRAULIC COMPONENTS AND DESCRIPTION10 F 10*(10F)

INPUT OUTPUT

Figure 3.1 2 D Model

Figure 3.2 Applied pressure exerted equally in all directions

6
 The 2D model of Automated hydraulic jack is shown in fig 3.1. A hydraulic jack is a
mechanical device used to lift heavy loads. It is a device that uses specific fluids to push
against piston. It works on the principle of Pascal’s law. It states that the pressure applies on
closed fluid is transmitted and undiminished in every direction and acts with equal force and
same area. In recent times the use of hydraulic system Is widely spread across countries. In
this system the use of oil act as a power transmission in industries. Hydraulic system is a
good choice for lifting heavy machineries, it is more efficient compared to pneumatic set up
machines. Pneumatic setup uses compressed air to move the piston. Usage of hydraulic
machineries in industries can achieve mass production and more efficiency. There are many
types of jacks like scissor jack, floor jack, highlight jack, hydraulic bottle jack. Among these
hydraulic bottle jacks is portable, cheaper, easy to use.
 Liquids are practically incompressible.

 The applied pressure is transmitted equally in all directions at once.

Figure 3.2 illustrates the application of these principles to a closed hydraulic system.
Two cylinders each are having a base whose area is 1 square inch, are connected by a tube.
The cylinders are filled with liquid to the level shown, and a piston with a base of the same
area (1 square inch) is placed on top of each column of liquid. Then a downward force of 1
pound is applied to one of the pistons. Since this piston has an area of 1 square inch, the
pressure upon it is 1 pound per square inch; and since the other piston is of equal area, the
same pressure, 1 pound per square inch, will be imposed upward upon it. Transmission of
equal pressures to equal area is shown in Fig 3.3.

Fig 3.3 Transmission Equal pressure to Equal Area

7
3.1.1 MULTIPLE UNITS

It is not necessary to confine our system to a single line from the source of hydraulic

power. Hydraulic power may be transmitted in many directions to do multiple jobs. Let us

connect one cylinder to four others as in Figure 3.4. Here we apply a force against the piston

in the large cylinder. The pressure from the large cylinder is transmitted equally to each of

the pistons in the other four cylinders as shown in Fig 3.4.

Figure 3.4 Multiple Units from a Single Source of Power

On the basis of the explanation of basic hydraulic principles just given, it is possible
to construct a simple, workable hydraulic system which will operate some mechanical
device. For example, such a system might open and close a door, and hold it in either
position for any desired interval.

TYPES OF HYDRAULIC CYLINDER

SINGLE ACTING HYDRAULIC CYLINDER

The Single Acting hydraulic cylinder (see Figure 3.5), which is the simplest type of
hydraulic motor, contains a spring-loaded piston, with a piston Rod that extends through one
end of the cylinder. In our project, this single acting hydraulic cylinder is used.

Figure 3.5 Single Acting Hydraulic Cylinder

8
 This piston rod, when connected to the door, supplies the mechanical motion which
opens and closes the door. The surface of the piston in contact with the hydraulic fluid has
an area of 2 square inches. The cut-out valve is hand-operated. When closed, it shuts off the
line between the actuating cylinder and the supply tank, preventing the oil under pressure in
the cylinder from escaping into the return line; when opened, it releases this pressure,
allowing the loading spring inside the cylinder to expand, and the oil in the cylinder to
escape back into the supply tank.

DOUBLE ACTING HYDRAULIC CYLINDER

In the simplified system, the door was actuated by a single acting cylinder. Oil was
kept in or released from the cylinder by a simple "on-and-off" valve. For more efficient and
positive actuation, this will be replaced by a double acting cylinder (see Figure 3.6). In such
a cylinder, the piston can move in either direction to open or close the door.

Figure 3.6 Double Acting Hydraulic System

The piston is locked in the desired position by the hydraulic fluid, which enters either
side of the piston as required and remains there until forced out. Since the flow of the fluid
must be directed to either of two sides, a valve, which selects the direction of flow, is
installed in the line. This is called a control valve. Control valves vary with the specific
application, but generally they are equipped with four ports. Two are connected to the
actuating cylinder at either side of the piston. A third port is the pressure port and

9
receives fluid from the pump. The fourth port returns surplus fluid either back to the
reservoir or elsewhere in the system.

THE RECIPROCATING PUMPS

The simplest practical application of this principle is seen in the hand-operated
reciprocating pump, a simplified version of which is illustrated in Figure 3.7. Here the inlet
and outlet ports in the cylinder, or pump body, are both in the same side of the piston. The
piston makes a close sliding fit within the cylinder, reducing leakage to a minimum, since
excessive leakage destroys the efficiency of a pump. Both the inlet and outlet ports are
equipped with check valves which permit the liquid to flow in one direction only, as shown
by the arrows.

Figure 3.7 Hand-Operated Reciprocating Pump

Assume that the intake side of the pump is connected to a supply of liquid. When we
move the piston to the right, lower pressure is created in the chamber formed by the piston.
Higher pressure on the fluid outside the chamber forces fluid in through the inlet port and
fills the chamber. Moving the handle forward in the opposite direction forces the fluid out. A
check valve at the inlet port prevents flow there and, since the fluid must find an outlet
somewhere, it is forced out through the discharge port. The check valve at the discharge
port prevents the entrance of fluid into the pump on the subsequent suction stroke.

10
The back-and-forth movement of the piston in the pump is referred to as reciprocating
motion and this type of pump is generally known as a reciprocating-type piston pump. It may
have a single piston or be multi-pistoned. It may be hand-actuated or power-driven. The
reciprocating piston principle is conceded to be the most effective for developing high fluid
pressures.

11
 CHAPTER-4

AUTOMATED HYDRAULIC JACK COMPONENTS AND

DESCRIPTION
THE MAJOR COMPONENTS OF THIS PROJECT ARE
Single acting Hydraulic Cylinder

Oil Tank

Hydraulic Pump with Motor

Connector

SINGLE ACTING HYDRAULIC CYLINDER

The Single Acting hydraulic cylinder (see Figure 3.5), which is the simplest type of
hydraulic motor, contains a spring-loaded piston, with a piston Rod that extends through
one end of the cylinder. In our project, this single acting hydraulic cylinder is used.

OIL TANK

The hydraulic system requires the oil to work the system. So, we have to provide the oil

tank.

HYDRAULIC FLUIDS

Almost any free-flowing liquid is suitable as a hydraulic fluid, as long as it will not
chemically injure the hydraulic equipment. For example, an acid, although free-flowing,
would obviously be unsuitable because it would corrode the metallic parts of the system.
Water, except for its universal availability, suffers from a number of serious defects as a
possible hydraulic fluid. One such defect is that it freezes at a relatively high temperature,
and, in freezing, expands with tremendous force, destroying pipes and other equipment.
Also, it rusts steel parts; and it is rather heavy, creating considerable amount of inertia in a
system of any size. The hydraulic fluid used in submarine hydraulic systems is a light, fast-
flowing lubricating oil, which does not freeze or even lose its fluidity to any marked degree
even at low temperatures, and which possesses the additional advantage of lubricating the
internal moving parts of the hydraulic units through which it circulates. Since this oil,

12
a petroleum derivative, causes rapid deterioration of natural rubber, synthetic rubber is
specified for use in these systems as packing and oil seals.

HYDRAULIC PUMP WITH MOTOR

In our project, the rotary vacuum pump with motor can be use Pumps using the

vacuum principle are popular because of their quiet performance and because their

simplicity of design results in relative freedom from service troubles.

CONNECTORS

In our system there are two types of connectors used; one is the hose connector and
the other is the reducer. Hose connectors normally comprise an adapter (connector) hose
nipple and cap nut. These types of connectors are made up of brass or Aliminium or
hardened steel. Reducers are used to provide inter connection between two pipes or hoses
of different sizes. They may be fitted straight, tee, “V” or other configurations. These
reducers are made up of gunmetal or other materials like hardened steel etc. The simple
hydraulic jack model is shown in fig 4.1.

Figure 4.1 Simple Hydraulic Jack Model

13
RELATION BETWEEN LIFTING FORCE AND PISTON PUMP FORCE

P1 =P2 (by Pascal’s law which is pressure will be

same at entry and exit) F1/A1 = F2/A2

F2=F*A2/A1

F2 = F1*π R22 / π

R21 F2 = F1*R22/R21

Whereas,

P1 = P2 = Pressure

F1 = Force on input piston pump

F2 = Lifting Force on output piston

A1 = Cross-sectional area of piston pump

A2 = Cross-sectional area of piston valve in outlet pump

R1 = Radius of input piston

R2 = Radius of output piston

14
 Figure 4.2 Design Bending Moment Diagram for Hydraulic Jack

Whereas,

FILA → Force applied by input lever arm

FOLA → Output force produced in the piston

Summing moments about Point A;

Σ MA = 0 = (FOLA * l1) – (FILA * l2)

or

(FOLA * l1) = (FILA * l2)

or

FOLA / FILA = l2 / l1

15
The 3D design and drafting representation of automated hydraulic jack is shown in fig 4.3 & 4.4.

FIGURE 4.3 Proposed Design of Automated Hydraulic Jack

FIGURE 4.4 Drafting Representation of Automated Hydraulic Jack

16
WORKING PRINCIPLE
Some of the general properties of liquids in open containers have been described. It

remains to discuss how a liquid will behave when confined, for, example, in an enclosed

hydraulic system. Liquids are practically incompressible. The following two basic

principles will help to explain the behavior of liquids when enclosed:

 Liquids are practically incompressible in the pressure ranges being considered.

Stated simply, this means that a liquid cannot be squeezed into a smaller space than

it already occupies.

 Therefore, an increase in pressure on any part of a confined liquid is transmitted

undiminished in all directions throughout the liquid (Pascal's principle). For

example, if pressure is applied at one end of a long pipe, the liquid, being practically

incompressible, will transmit the pressure equally to every portion of the pipe.

METHODOLGY
In normal conventional hydraulic jack, the intensity of pressure is transformed
uniformly in all directions through a mass of fluid. In this study, Pascal's Law Concept is
used to examine the lift force. Also, this study analyses hydraulic system components or
hydraulic telescopic capabilities to better the hydraulic jack's capability. The simple
automation work of jack can be done with the motor drive mechanism. The goal of this
research is to design the hydraulic portable gadget to facilitate the mechanics in car
maintenance and repair notably a component of the bottom machine. The data collection
can be done by directly assessing the performance test of the portable automated hydraulic
jack in automobiles and compared with the original jack. Also, some of the systems can be
work by integrating the hydraulic principle to the scissor-based jack, this will work by
transferring the hydraulic pressure with the help of hydraulic cylinder to the scissor jack
mechanism, this will be useful for lifting the light weight automobiles for servicing or
repair kind purpose, it can be handled indoor as well as outdoor.

17
In order to assist the elderly and physically disabled, this project's automatic hydraulic jack
mechanism is more beneficial. So, they made an effort to seize the chance. This system can
also be integrated with wiper motor as a driving mechanism for operating hydraulic jack.
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
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,

 Brazability,

 forge ability,

 merchantability,

 surface properties,

 shrinkage,

 Deep drawing etc.

18
 CHAPTER 5

SOME OF THE FACTORS AFFECTING AUTOMATED HYDRAULIC

JACK

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.

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

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.

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

5.1.4 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 the designed part are involved in the selection of
proper materials.

19
GENERALLY USED MATERIALS

The table (5.1, 5.2, 5.3, 5.4, 5.5) explains the generally used materials and type of
materials used for the fabrication.

TABLE 5.1 CYLINDER TUBE MATERIALS

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Plastic Hard drawn brass tube hard drawn brass tube.

2. Hard drawn Aluminium Hard drawn steel tube

Aluminium tube Castings tube.

4. Hard drawn Brass, Bronze, Iron or

Brass tube Castings, welded steel tube

TABLE 5.2 END COVER MATERIALS

LIGHT DUTY MEDIUM DUTY HEAVY

1. Aluminium stock Aluminium stock Hard tensile

(Fabricated) (Fabricated) Castings

2. Brass stock Brass stock

( Fabricated) (Fabricated)

3. Aluminium Aluminium, Brass,

Castings iron or steel Castings.

20
 TABLE 5.3 PISTON MATERIALS
LIGHT DUTY MEDIUM DUTY HEAVY DUTY
[Link] Aluminium Castings Aluminium Forgings,
Castings Brass (Fabricated) Aluminium Castings.
2. Bronze (Fabricated) Bronze (Fabricated)
3. Iron and Steel Brass, Bronze, Iron or
Castings Steel Castings.

TABLE 5.4 MOUNT MATERIALS

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminium Aluminium, Brass High Tensile

Castings And Steel Castings Steel Castings

2. Light Alloy High Tensile

(Fabricated) Steel Fabrication

TABLE 5.5 PISTON ROD MATERIALS

MATERIAL FINISH REMARKS

MILD STEEL Ground and polished Generally preferred chrome plated

hardened, ground and polished.

STAINLESS STEEL Ground and Polished Less scratch resistant than

chrome plated piston rod

21
ADVANTAGES AND DISADVANTAGES

ADVANTAGES

 It requires simple maintenance cares

 The moving parts of this system are cooled by the oil itself used. Thus, this
project does not require any cooling arrangements.
 The loaded light vehicles can be easily.
 Checking and cleaning are easy, because of the main parts are screwed.
 Handling is easy.
 Manual power not required
 Repairing is easy.
 Replacement of parts is easy.
 Maximum height up to 1.5 feet can be reached.
 No Oil wastage.

DISADVANTAGES

1. Initial cost is high.

2. High maintenance cost.
3. Chances of oil leakage

APPLICATIONS

 It is very much useful for Car Owners & Auto-garages. This automatic -hydraulic
jack is used for lifting the vehicles.
 It can be applicable for all types of automotive vehicles like SUV, XUV,
TEMPO TRAVEL, AUTO RICKSHAWS.
 The given below table 5.6 refers the list of materials used for the Automated
hydraulic jack.

22
 TABLE 5.6 LIST OF MATERIALS

Sl. No. PARTS Qty. Material

i. Hydraulic Cylinder 1 Aluminium

ii. D.C Motor 1 Cast Iron

iii. Hose Collar and Reducer - Brass

iv. Stand (Frame), clamps and holders - Mild steel

v. Switch - Plastic or metal

vi. Battery 1 Plastic

TYPES OF COST OCCUR DURING PROJECT

MATERIAL COST

Raw materials like mild steel, copper, bronze, fasteners and hydraulic system

components

LABOUR COST

Lathe, Drilling, Welding, Grinding, Power Hacksaw, Gas cutting:

OVERHEAD CHARGES
The overhead charges are arrived by “Manufacturing cost”
Manufacturing Cost = Material Cost + Labor cost

TOTAL COST
Total cost = Material Cost + Labor cost + Overhead Charges

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 CHAPTER 6

SUMMARY

Automated jack system is a simple and compactable design, some of them can
propose miniature inbuilt jack models, and some of them can propose automated jack
models. the reason why inbuilt jack system doesn’t have the tendency to perform well is due
to its additional weight in automobile and also ground clearance issues. These problems can
be simply rectified by installing a automated system in conventional hydraulic jack. A typical
locomotive mechanism that can be able to convert the output into reciprocating motion that
will able to drive the jack into automated manner. Since it takes power from car battery itself,
so no any additional power source is required. it reduces man power, time saving, easy to
operate and able to lift the vehicle. By altering and improving the design modification and
testing in future we can integrate this system to power brakes also, so the hydraulic fluid will
circulate for car brakes and also for power lifting.

CONCLUSION
This project work has provided us an excellent opportunity and experience, to use our
limited knowledge. We gained a lot of practical knowledge regarding, planning, purchasing,
assembling and machining while doing this project work. We feel that the project work is a
good solution to bridge the gates between institution and industries. In conclusion remarks of
our project work, let us add a few more lines about our impression project work. Thus, we
have developed an “DESIGN AND DEVELOPMENT OF AUTOMATIC HYDRAULIC
JACK” which helps to know how to achieve low-cost automation. The operating procedure
of this system is very simple, so any person can operate. By using more techniques, they can
be modified and developed according to the applications.

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