Professional Documents
Culture Documents
DIPLOMA
IN
MECHANICAL ENGINEERING
BY
2004-2005
DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE
Register number:
_________________________
Mr. /Ms._______________________________
_________________ _______________
Head of Department Guide
Coimbatore –641651.
Date:
ACKNOWLEDGEMENT
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ACKNOWLEDGEMENT
CONTENTS
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CONTENTS
ADKNOWLEDGEMENT
1. SYNOPSIS
2. INTRODUCTION
6. FABRICATION
7. ASSEMBLING PROCEDURE
8. PRINCIPLE OF WORKING
10. APPLICATIONS
11. MAINTENANCE
14. DRAWINGS
15. CONCLUSION
BIBLIOGRAPHY
PHOTOGRAPHY
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SYNOPSIS
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SYNOPSIS
This project work titled “FABRICATION OF HYDRUALIC PALLET
TRUCK” has been conceived having studied the difficulty in lifting the any type of
Our survey in the regard in several automobile garages, machines, revealed the
facts 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. Such that the vehicle can be lifted from the floor land without
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.
The subsequent chapters indicate all the essential features of its fabrication,
INTRODUCTION
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INTRODUCTION
This device the HYDRAULIC FORK LIFT for automobile garages has been
developed to later the needs of small and medium automobile garages, who are normally
In most of the garages the vehicles and machines are lifted by using screw jack or
In order to avoid all such disadvantages, This, HYDRAULIC FORK LIFT has
been designed in such a way that it can be used to lift the vehicles or machines very
smoothly without any impact forces. The operation is made be simple that even an
unskilled labour can handled, by just demonstrating the working of the HYDRAULIC
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
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,
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
electricity and air in the preceding paragraphs, fully justify the addition of this third
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
fluid motion. There are hydraulic principles that explain the action of fluids in motion and
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
task such as steering a submarine or opening the outer door of a torpedo tube.
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
A thin bottle is filled to the top with a liquid and tightly corked. A lever is pressed
against the cork to apply a downward force. If sufficient pressure is exerted, the bottle
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
Multiple units
against the piston in the large cylinder. The pressure from the large cylinder is transmitted
(see Figure 4). The foot pressure on the brake pedal (1) depresses a piston (2) in the
Fluid is forced through the lines (4) into each of the brake cylinders (5). At the
brake cylinder, two opposed pistons (6) attached to the brake shoes are forced outward,
pressing the brake bands (7) against the inside of the wheels (8) to stop their rotation by
friction. Removal of the foot pressure allows springs (9) at each wheel to restore the
pistons to their original positions and returns the fluid to the master cylinder where it is
1) Brake pedal; 2)
piston; 3) master
cylinder; 4) hydraulic
line; 5) brake cylinder;
6) brake piston; 7)
brake band; 8) wheel;
9) return spring.
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
equipment, which, in one form or another, will be found in every hydraulic system:
as needed and into which the oil from the return line flows.
Figure 5 A simple
hydraulic system
direction.
other.
The supply tank must have a capacity large enough to keep the entire system filled
with oil and furnish additional oil to make good the inevitable losses from leakage. The
tank is vented to the atmosphere; thus atmospheric pressure (14.7 pounds per square inch)
forces the oil into the inlet, or suction, side of the pump, in accordance with the principle
explained in connection with Figure 3. The tank is generally placed at a higher level than
the other units in the system, so that gravity assists in feeding oil into other units.
The Single Acting hydraulic cylinder (see Figure 6), 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 6 Single acting hydraulic cylinder
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
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
found in actual service. It has the obvious disadvantage that instantaneous opening of the
hand pump, a double acting actuating cylinder for the spring-loaded single acting
cylinder in Figure 5, and including a control valve, an unloading valve, and an automatic
relief valve, in addition to the supply tank, or reservoir, and the return line check valve,
Figure 7. Power-driven
hydraulic system
Automatic pumping will give immediate pressure for use at the actuating cylinder
whenever it is needed.
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 8). In
such a cylinder, the piston can move in either direction to open or close the door.
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 receives fluid from the pump. The fourth port returns surplus
reciprocating pump, a simplified version of which is illustrated in Figure 1-15. Here the
inlet and outlet ports in the cylinder, or pump body, are both in the same side of the
Both the inlet and outlet ports are equipped with check
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
The check valve at the discharge port prevents the entrance of fluid into the pump
on the subsequent suction stroke. The back-and-forth movement of the piston in the pump
The following are the different driving mechanisms for imparting reciprocating
2. eccentric drive
4. Cam drive
6. Screw drive
8. Hydraulic drive
The crank and connecting rod mechanism illustrated in fig. 5A is the simplest and
most common method of driving the ram. For multiple purpose dies, a double crank may
be used.
Eccentric drive:
advantage near the bottom of the stroke. The presses fitted with kunckle joint drive are
Cam drive:
The cam drive illustrated in fig.6B is used to give a specific type of movement to
the ram. The ram remains idle for some period at the bottom of the stroke.
Toggle drive:
The toggle drive illustrated in fig.7A is mainly used in drawing operations for
Screw drive:
The screw drive illustrated in fig.7B is operated by a friction disc which imparts a
uniform accelerating movement to the ram in the downward stroke. The screw driven
The rack and pinion drive illustrated in fig. 8A is used for imparting a very long
Hydraulic drive:
The hydraulic drive, illustrated in fig. 8B is used for applying a very large pressure
at a slow speed for forming drawing operations, etc. The oil under high pressure is
pumped on one side of the piston and then on the other to impart reciprocating movement
to the ram.
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COMPONENTS AND
DESCRIPTION
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COMPONENTS AND DESCRIPTIONS
Hydraulic Jack
o Hydraulic Cylinder
o Ram
o Oil Tank
o Plunger Pump
o O-Ring
o Handle
L-Link Plate
Wheels
1. HYDRAULIC JACK:
HYDRAULIC CYLINDER:
It is already briefly explained the above chapter.
RAM:
The ram is the lifting parts of this project. It is fixed to the L-angle
flat form.
OIL TANK:
The oil tank is provided in the hydraulic jack inside. The hydraulic
system requires the oil to work the system. So we have to provide the oil
tank.
Hydraulic fluids
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
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
Since this oil, a petroleum derivative, causes rapid deterioration of natural rubber,
synthetic rubber is specified for use in these systems as packing and oil seals.
PLUNGER PUMP:
This is known as the input component of this project i.e. from the power is
transmitted to the right of the cylinder, the oil is draw from the reservoir through
pumping the handle provide at the right side of the pump plunger.
The pump is welded on the right side of the cylinder. The length of stroke of the
pump handle is depends upon the length of the plunger used. For this a flexible pivoting
arrangement is provided behind the pump. The material used for pump block is mild
steel.
O-RING:
The “O” rings are fitted into the grooves of plunger pump to maintain perfect seal
between the plunger and the outer wall. They are mostly made up of neoprene rubber.
It is made up of mild steel. This is used to release the hydraulic pressure, so that
HANDLE:
This is also made upof mild steel. This handle is used to lifting the ram from
downwards position to upward position. This handle is used to pull the plunger pump.
The loading/unloading materials are kept in this flat form. This flat form is linked to the
3. L-LINK PLATE:
The L-Link plate is used to joint the flat form and hydraulic jack with the help of
suitable arrangement. This L-Link plate is welded one side to the flat form and another
4. WHEELS:
Wheels are provided at the bottom of the side plates for moving the pallet truck.
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FABRICATION
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FABRICATION
2. L-Link Plate
3. Top Plate
FABRICATION:
PROCESS INVOLVED
1. Hacksaw Cutting
2. Grinding
3. Welding
The two plates are made to the required shape as per the drawing by hacksaw
PROCESS INVOLVED
1. HACKSAW CUTTING
2. GRINDING
3. DRILLING
4. WELDING
The two arm plates are made to the prescribed shape as shown in the drawing by
hacksaw cutting and grinding. The grinding process is done by using floor stand grinding
machine.
After that processes is carried out in the link plates by using drilling machines, the
3. TOP PLATE:
PROCESS INVOLVED
1. HACKSAW CUTTING
2. GRINDING
3. DRILLING
4. WELDING
The top plate is made to the prescribed shape as shown in the drawing, by
hacksaw cutting and grinding. The grinding process is done by floor stand grinding
machine. After that processes is carried out in the flat form plates by using drilling
4. WHEELS:
PROCESS INVOLVED
1. WELDING
The wheels are welded to the required dimensions by using arc welding.
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ASSEMBLING PROCEDURE
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ASSEMBLING PROCEDURE
First the hydraulic jack with handle is mounted on the bottom plate by using
Then the flat plate is mounted to the hydraulic jack with the help of bolts and nuts.
Then bolt is tightened to the each end. The three wheels are mounted in the wheel rods of
the bottom plate and then the cotter-pins inserted in the wheel rods to stop the sliding of
PRINCIPLE OF WORKING
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PRINCIPLE OF WORKING
PRINCIPLE
PASCAL’S LAW:
“It states that the intensity of pressure at any point in a fluid at rest is the same in
all direction”
WORKING PRINCIPLE:-
Hydraulic jack consists of piston, piston rod, screw rod and hydraulic oil. The
hydraulic jack reciprocating handle is move upward and downward continuously, so that
hydraulic jack piston forward. The L-Link plate is joint the top plate and flat form. The
1. Before operating the jacks first insert the notched end of the handle into the
release valve, turn the operating handle clock wise until release valve is closed.
2. Insert operating handle into the socket and the ram is steadily raised by the
load is thus raised; the ram will stop rising when the required height is reached.
3. Lower the ram by turning the release valve. Counter-clockwise with the
notched end slacken it slowly when a load is applied or accidents would occur.
4. Before operating, estimate the weight of the load. Do not overload the jack
5. Select point of action according to the gravitational centre place the jack on the
hardness ground If necessary, place a hard plank under the jacks so as to avoid
the different jacks at an equal speed with equal load. Otherwise, there is
7. For best results use specifically blended jack oil. If such oil is not readily
ADVANTAGES
4. Checking and cleaning are easy, because of the main parts are screwed.
5. Handling is easy
7. Repairing is easy.
place.
DISADVANTAGES
APPLICATIONS
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APPLICATIONS
1. It is very much useful in auto-garage. This trolley pallet truck is used for lifting
the vehicles.
MAINTENANCE
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MAINTENANCE
1. The level of oil in the tank should be checked once in a week and if any
3. The welding Joints should be checked once in a month for any leakage.
5. A special case should be taken on the relief valve and the openings of
6. Before changing the fluid the whole unit should be thoroughly cleared.
7. Grease should be checked every day for the moving parts like wheels
and etc.
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LIST OF MATERIALS
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LIST OF MATERIALS
Sl. No. COMPONENT QUANTITY MATERIAL
1. Bottom Plate 1 M.S.
2. Flat Form 1 M.S.
3. Wheels 3 Nylon
4. L-Link Plate 1 M.S.
5. Top Plate 1 M.S.
6. Pumping Handle 1 M.S.
7. Hydraulic Jack 1 M.S.
8. BOLT & NUT - M.S
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COST ESTIMATIONS
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COST ANALYSIS
No. (RS.)
1. Bottom Plate 1 M.S.
2. Flat Form 1 M.S.
3. Wheels 3 Nylon
4. L-Link Plate 1 M.S.
5. Top Plate 1 M.S.
6. Pumping Handle 1 M.S.
7. Hydraulic Jack 1 M.S.
8. BOLT & NUT - M.S
TOTAL COST RS.
2. LABOUR COST
3. OVERHEAD CHARGES
DRAWINGS
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CONCLUSION
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CONCLUSION
operation and safety, hence the results has given a clear indication of its commercial
viability. The cost analysis has shown its economic feasibility and we are under the
BIBLIOGRAPHY
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BIBLIOGRAPHY
Web site:
www.maritime.org
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PHOTOGRAPHY
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PHOTOGRAPHY