A
MICRO PROJECT REPORT
ON
“Prepare Demonstration Model Of Telescopic Cylinder
Using Pvc Pipes Work Shop Based”
SUBMITTED BY
MR YASH JAYANT KALE
(DIPLOMA IN MECHANICAL ENGG)
DEPARTMENT OF MECHANICAL ENGINEERING
GAUTAM POLYTECHNIC INSTITUTE, GAUTAMNAGAR.
2024-25
1
KSKESS
GAUTAM POLYTECHNIC INSTITUTE, GAUTAMNAGAR
CERTIFICATE
This is to certify that MR. YASH JAYANT KALE (DIPLOMA IN MECHANICAL ENGG) Has
successfully completed MICRO PROJECT REPORT On Prepare
Demonstration Model Of Telescopic Cylinder Using Pvc Pipes
Work Shop Based During the academic year 2024-25. This is in partial
fulfillment of the requirement for DIPLOMA IN MECHANICAL ENGG course as
per syllabus laid by M.S.B.T.E.
Prof.Raktate V.V. Prof. Joshi.G.R Prof. BHARTI S.M
Gudies HOD Principal.
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ACKNOWLEDGEMENT
I would like to express my special thanks of gratitude to my prof.
Raktate V.V., who gave me the golden opportunity to do this wonderful
project of Prepare Demonstration Model Of Telescopic Cylinder
Using Pvc Pipes Work Shop Based Who also helped me in completing
my project. I came to know about so many new things I am really thankful
to them.
Secondly I would also like to thank .Prof. Joshi.G.R , Prof.Bharti .S.M
MR. YASH JAYANT KALE
(DIPLOMA IN MECHANICAL ENGG)
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INDEX
Sr. Constant Page No
No
01 Abstract 05
02 Introduction 06
03 Working principle 07
04 Schematic Diagram 8
05 Telescopic Cylinder 10
06 Conclusion 16
07 References: 17
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Abstract
The use of hydraulic jack in the industry is widespread as load lifting structures.
Telescopic hydraulic jack is a special design of jack with a series of tubes of
progressively smaller diameters nested within each other. They have long stroke
from a compact initial package, which have attracted a lot of attention for their
applications as load lifting structures.
Design and analysis of telescopic hydraulic cylinder is very complex
phenomenon that involves interactions between the two stages. In this project
telescopic jack is designed for the industry “Hydrau Solutions” located in
Belgaum. Principle parameters included the maximum lifting capacity of 7000 Kg
and a stroke of 980 mm.
5
Introduction
A telescopic hydraulic jack uses a liquid to push against a piston. This is based
on Pascal’s Principle. The principle states that pressure in a closed container is the
same at all points. If there are two cylinders connected, applying force to the smaller
cylinder will result in the same amount of pressure in the larger cylinder. However,
since the larger cylinder has more area, the resulting force will be greater. In other
words, an increase in area leads to an increase in force. The greater the difference in
size between the two cylinders, the greater the increase in the force will be. A
hydraulic jack operates based on this two cylinder system.
As expected, results show that load carrying capability of the jack is
significantly affected by different stress acting on it. Finite element results were in
good agreement with the theoretical solution for the telescopic jack under different
stress.
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Working Principle
Telescopic hydraulic jack
The advantage of telescopic hydraulic is their ability to provide an exceptionally long
stroke from a compact initial package as shown in fig 2. The collapsed length of typical
telescopic cylinders varies 20% to 40% of their extended length. This finds application
when mounting space is limited, and the application needs a long stroke.
Single-Acting Telescopic Cylinders
High pressure oil from the pump is directed by the control valve through the port
(A) to fill the cylinder. Any air in the system is trapped in the end of the cylinder (B)
and may be bled off through the bleeder valve (C) as shown in fig 1.
Fig- showing extension of single acting telescopic cylinder
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Oil pushes on the bottom of the sleeve or plunger forcing it to move out. The
outside diameter or sealing area of the moving sleeve or plunger (D) determines the
effective area
Fig- extension of 1st stage of single acting telescopic cylinder
As the sleeve or plunger moves out, the oil trapped between (E) the sleeve or
plunger wall is released through transfer holes (G) which are drilled in the
sleeve or plunger (fig 5). Under normal operating conditions the largest diameter
moving sleeve extends first, then the next largest sleeve, etc.
Fig-5 showing extension of single acting telescopic cylinder
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So at a given PSI (pressure) and LPM (liters per min.) the cylinder will develop less
force and increase in speed as it changes to the next moving stage.
Fig -6 fully extended single acting telescopic cylinder
Schemetic Diagram
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Telescopic cylinder
Telescopic cylinders are a special design of a hydraulic cylinder or pneumatic
cylinder which provide an exceptionally long output travel from a very compact
retracted length. Typically the collapsed length of a telescopic cylinder is 20 to 40% of
the fully extended length depending on the number of stages.[1] Some pneumatic
telescoping units are manufactured with retracted lengths of under 15% of overall
extended unit length.[2] This feature is very attractive to machine design engineers
when a conventional single stage rod style actuator will not fit in an application to
produce the required output stroke.[1]
Telescopic cylinder (ISO 1219symbol)
Heavy duty telescopic cylinders are usually powered by hydraulics, whereas some
lighter duty units could also be powered by compressed air.[3]
Telescopic cylinders are also referred to as telescoping cylinders and multi-stage
telescopic cylinders.
An application for telescopic cylinders commonly seen is that of the dump body on
adump truck used in a construction site. In order to empty the load
of gravelcompletely, the dump body must be raised to an angle of about 60 degrees.
To accomplish this long travel with a conventional hydraulic cylinder is very difficult
considering that the collapsed length of a single stage rod cylinder is approximately
110% of its output stroke.[1] It would be very challenging for the design engineer to fit
the single stage cylinder into the chassis of the dump truck with the dump body in
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the horizontal rest position. This task is easily accomplished, however, using a
telescopic style multi-stage cylinder.[4]
Design and technical terminology
Telescopic cylinders are designed with a series of steel or aluminum[2] tubes of
progressively smaller diameters nested within each other. The largest diameter sleeve
is called the main or barrel. The smaller inner sleeves are called the stages. The
smallest stage is often called the plunger[4] or piston rod.
Showing the telescopic principle, an object collapsed (top) and extended (bottom),
providing more reach
The cylinders are usually mounted in machinery by pivot mounts welded to the end or
outer body of the barrel as well as on the end of the plunger.
Telescopic cylinders are commonly restricted to a maximum of 6 stages. 6 stages are
commonly thought to be the practical design limit as stability problems become more
difficult with larger numbers of stages. There are exceptions however, with one
pneumatic cylinder manufacturer successfully incorporating up to 9 stages in their
cylinder designs.[2]
Telescopic cylinders require careful design as they are subjected to large side forces
especially at full extension. The weight of the steel bodies and the hydraulic
oil contained within the actuator create moment loads on the bearing surfaces between
stages. These forces, combined with the load being pushed, threaten to bind or even
buckle the telescopic assembly. Sufficient bearing surfaces must therefore be
incorporated in the design of the actuator to prevent failure in service due to side
forces. Telescopic cylinders must only be used in machinery as a device for
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providingforce and travel. Side forces and moment loads must be minimized.
Telescopic cylinders should not be used to stabilize a structural component.[5]
Hydraulic telescopic cylinders are often limited to a maximum hydraulic pressure of
2000-3000 psi. This is because the outward forces produced by internal hydraulic
pressure tends to expand the steel sleeve sections. Too much pressure will cause the
nested sleeves to balloon outward, bind the mechanism and stop moving. The danger
exists that a permanent deformation of the outer diameter of a sleeve could occur, thus
ruining a telescopic actuator. For this reason, care must be taken to avoid shock
pressures in a hydraulic system using telescopic cylinders. Often such hydraulic
systems are equipped with shock suppressing components, such as hydraulic
accumulators, to absorb pressure spikes.[6]
Basic design types of telescopic cylinders
Telescopic cylinders can usually be classified into two basic designs: single acting and
double acting. A number of other special designs also exist including a hybrid
single/double acting design, and a constant speed, constant thrust design.[4]
Single-acting
Single acting telescopic cylinders are the simplest and most common design. As with a
single acting rod style cylinder, the single acting telescopic cylinder is extended using
hydraulic or pneumatic pressure but retracts using external forces when the fluid
medium is removed and relieved to the reservoir. This external retraction force is
usually gravity acting on the weight of the load. This external weight must obviously
be sufficient to overcome the friction and mechanical losses within the machine design
even after the work portion of the machine cycle has been accomplished. In the
example above of the dump truck, the weight of the dump body, now raised at an
angle of 60 degrees but empty of the load, must be enough to force the
unpressurized hydraulic fluid out of the cylinder and cause it to retract to the fully
collapsed position.[7]
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Double-acting
A double acting cylinder is extended and retracted using hydraulic or pneumatic
pressure in both directions. Double acting telescopic cylinders are thus much more
complex in design than the single acting type. This additional complexity is due to the
requirement of adding retracting piston faces to all of the cylinder stages and the
difficulty in supplying pressurized fluid to the retraction pistons of the intermediate
stages.[4]
To accomplish the double acting feature, additionalhydraulic seals are added to
internally seal off the individual stages. In addition, internal air or oil passageways are
machined so that as each stage completes retracting, a passage is open to supply the
next stage with pressurized fluid to retract. Thus a double acting telescopic actuator
usually retracts starting from the smallest diameter stage to finish with the largest
stage retracting lastly. Because the seals used to accomplish this must pass over these
internally machined fluid transfer holes, the seals are usually made from hard
materials to resist wear and abrasion. They are often iron rings or glass
reinforced nylonseals.[4]
The extension and retraction fluid supply ports on double acting hydraulic telescopic
cylinders are usually located at opposite ends of the cylinder assembly. The extension
port is mounted at the base of the outer barrel and the retraction port is mounted in the
end of the plunger section. This can, in some applications, prove to be very difficult to
connect with hydraulic hoses due to the distance between these ports at full extension.
In such a circumstance, both ports can be located in the barrel. An internal passageway
must be fitted, however, so that the retracting fluid is supplied to the plunger section at
full extension. This special passageway is in itself a telescopic assembly that extends
with the cylinder and is outfitted with seals on the various stages.[4]
This additional complexity makes double acting telescopic cylinders very expensive.
They are usually custom designed for each application.
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Typical applications for double acting telescopic cylinders include the packer-ejector
cylinders in garbage trucks and transfer trailers, horizontal compactors,
telescopic excavator shovels, and roll-on/roll-off trucks. In all of these applications,
the cylinder operates near horizontally and thus gravity is not available to retract the
actuator. A double acting design is therefore required to both push and pull the
telescoping mechanism.[7]
Care must be taken when controlling most double acting telescopic design cylinders.
The effective retraction area is often much less than the extension area. Thus if
the hydraulic fluid return line is blocked during extension a pressure intensifying
effect can occur causing seal failure or even causing the metal sleeve to balloon
outward. The cylinder could thus be rendered unable to retract because of failed seals
or jam in position due to binding.[5]
Another problem can occur if a double acting telescopic cylinder encounters a load
that pulls on the actuator during extension such as when a tilting load goes over center
and opens the cylinder beyond the internal volume of the hydraulic oil. When the
piston face catches up again and strikes the oil column a pressure spike occurs which
can damage theactuator.[5]
Single- / double-acting combination
In some applications, a single acting telescopic cylinder is adequate to accomplish
the work except for one stage that is required to be double acting.
An example of this is erecting the mast of a large mobile drilling rig. The mast is
erected to the vertical position using a telescopic cylinder. However, to lower the
mast, gravity is not available for the initial tilt back from the vertical position. Thus,
the plunger stage only of the telescopic actuator is equipped as a double acting
cylinder to provide the initial force to pull the mast back from vertical. Once the tilt
back has been initiated, then gravity takes over and supplies the force to complete the
full cylinder retraction. The remaining stages, therefore, are single acting. This special
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combination is much less complex and much less costly than using an entirely double
acting design.[4]
Constant thrust, constant speed
In some special applications, a telescopic cylinder is required to extend with a
constant force or constant speed. To accomplish this the cylinder is designed so that all
the stages extend at the same time. This can also be accomplished in a double acting
design by matching the extension and retraction areas of the pistons on all the stages.[4]
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Conclusion
Telescopic hydraulic jack are a special design of jack which provide an
exceptionally long output travel from a very compact retracted length. Static
analysis of the telescopic hydraulic jack components, for the different loading
conditions, can be performed by using the commercial finite element packages if
the loads on the structure are properly defined. From the results presented in this
study, we can summarize that the commercial finite element packages can be used
to analyze the engineering structures that are subjected to combination of loads
with the proper definition of the loading conditions. A telescopic jack subjected
side load, hoop stress & radial pressure is analyzed with the finite element
package ANSYS. Good agreement is found between the results obtained by
ANSYS and Theoretical calculation. Hoop stress, pressure, compressive stress &
side load have significant impact on the design of the hydraulic cylinder.
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References
[1] Gane and Sarson (1979) “Structured systems analysis: tools & techniques”
[2] R.H Warring (1983) “Hydraulic Handbook” Gulf publishing company, London.
[3] Arora K R “Fluid Mechanics, Hydraulics and Hydraulic Machines”, In Metric Units
[4] Muchnik, J. (2007). History of Hydraulic Jacks.
[5] Ansys Inc., (1998). ANSYS theory manual release 5.4. Swanson Analysis
System. USA.
[6] T G Sitharam , L GovindRaju (2004) “Applied Elasticity” Interline Publishing
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𝑻𝒉𝒂𝒏𝒌 𝒀𝒐𝒖…….
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