International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 6, June 207, pp. 200 206, Article ID: IJMET_08_06_02 Available online at http://www.ia aeme.com/ijmet/issues.asp?jtype=ijmet&vtyp pe=8&itype=6 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 IAEME Publication Scopus Indexed DESIGN AND MANUFACTURING ELECTRICAL BOTTLE CAR JACK D.C. 2 VOLT Timur Choban Khidir Mechanical Department, Kirkuk University / College of Engineering, Iraq ABSTRACT The tire puncture problem of the cars on the roads, especially on the highway roads generally needs manual human force to solve the problem by using a mechanical scissor car jack. Our work focused on a bottle carjack and adapting D.C. motor (2 volts) with chain-sprocket set to design a suitable machine. Lifting the car to solve the puncture problem with this new machine is easier, safer, abbreviate the time and more reliable for persons who suffer from their health s. We used drilling, grinding, milling, and welding machines to make up this work. The designed jack had been tested on a passenger car and passed successfully. We used Solidworks software program to achieve the goal. Key words: Puncture, SOILDWORKS, D.C. motor, bottle carjack, chain-sproket. Cite this Article: Timur Choban Khidir. Design and Manufacturing Electrical Bottle Car Jack D.C. 2 Volt. International Journal of Mechanical Engineering and Technology, 8(6), 207, pp. 200 206. http://www.iaeme.com/ijm MET/issues.asp?JType=IJMET&VType=8&ITy ype=6. INTRODUCTION During side road emergency i.e. tire puncture the jack is used to raise the car. A mechanical scissor car jack is a device used to facilitate vehicle maintenances by lifting all or parts of a vehicle into the air []. Nowadays, different types of car jacks have been remodeled for raising vehicles from the land surface. Generally, the available carjacks manually operated by turning a lead screw which is needed to human effort to do requested job. So, the operator may hurt his back and beside that he spends more time to replace the punctured tire with the spare tire that exists in the car [2]. Hence, to save from the effort and the time it's needed to electrical portable jack which is necessary to repair the car on the side way [3]. Which is performed with electric D.C. motor (2 volts) with bottle carjack and this motor must hold the load more than 000 kg. This type of bottle carjack consistss of a power screw that converts the rotary motion to a linear motion. These jacks are compact in size, but are designed and built for performance to lift vehicles. The aim of this study is to remodel a car jack which is safe, able to lift and lowering the car without spending much human effort and easy to be operated. The design and analysis of modified carjack are discussed in this study. http://www.iaeme.com/ijmet/index.asp 200 editor@iaeme.com
Design and Manufacturing Electrical Bottle Car Jack D.C. 2 Volt 2. WORKING OF ELECTRICALLY OPERATED JACK When running the motor, transmission of movement of the motor to shaft caller with first sprocket and by chain starts picked up movement to the second sprocket, and thus the movement transition to jack and thus jack begins to lift a car. D.C. motor 2V receives electricity from the battery through the car. The bottle carjack also contains the gearbox and it helps the device to increase torque. 3. DESIGN AND DEVELOPMENT OF JACK Figure shows remodeled bottle jack. The main components required for the development of this jack are: Original bottle jack. Shaft arm for jack. Chain and Sprocket Set. D.C. Motor for windshield wiper motor (Window Motors) for bus. Base for jack and Sprocket Set. Table includes details of all components required for manufacturing the actual model or prototype of electrically operated bottle jack. Table List of components. Component No. Description Bearing 2 Base 3 Chain and Sprocket Set 4 D.C. Motor 5 Shaft arm 6 Bolt 7 Nut The isometric view of the bottle carjack is shown below: Qty. 2 3 2 Figure Isometric view of CAD model for Modified bottle jack http://www.iaeme.com/ijciet/index.asp 20 editor@iaeme.com
Timur Choban Khidir Figure 2 shows the actual model of electrically operated carjack. The prototype is manufactured by using the jack and bus windshield wiper motor. (a) (b) 4. SPECIFICATIONS Specifications of Sprocket and Chain Figure 2 Model factory of modified bottle jack Bottom Diameter of larger sprocket = 45 mm and Outside Diameter = 50 mm. Bottom Diameter of smaller sprocket = 30 mm and Outside Diameter = 35 mm. Center distances = 46 mm. No. of teeth of the largest sprocket = 24 No. of teeth of the smallest sprocket = 6 No. of chain link = 32 Material : Stainless Steel Specifications of Bottle Jack Overall height of Jack = 390 mm, Out diameter = 40 mm, in diameter = 38 mm, Material : cast carbon steel Specifications of D.C. Motor Power = 30 W, Torque = 6 N.m, Speed = 75 r.p.m. Voltage = 2 V http://www.iaeme.com/ijciet/index.asp 202 editor@iaeme.com
Design and Manufacturing Electrical Bottle Car Jack D.C. 2 Volt Figure 3 D.C. motor 5. ANALYSIS This section shows the details of FEA of this remodeled prototype. The FEA Method is the easiest technique to the theoretical method to determine the stress remodeled in various components of bottle jack. In this study FEA is carried out in SOILDWORKS to calculate the max. (stress, deformation and strain) in the main parts of the system when applied with boundary conditions. Steps in the Analysis Step : Analysis jack for 000 kg (Stress, deformation, Strain) Figure 4 Stress Analysis Figure 5 Deformation Analysis Figure 6 Strain Analysis http://www.iaeme.com/ijciet/index.asp 203 editor@iaeme.com
Timur Choban Khidir Step 2: Analysis jack for 2000 kg (Stress, deformation, Strain) Figure 7 Stress Analysis Figure 8 Deformation Analysis Figure 9 Strain Analysis Step 3: Analysis of torque for arm shaft jack: 6 N.m Figure 0 Stress Analysis Figure Strain Analysis http://www.iaeme.com/ijciet/index.asp 204 editor@iaeme.com
Design and Manufacturing Electrical Bottle Car Jack D.C. 2 Volt Step 4: Analysis torque of smaller sprocket for Outside Diameter 35 mm: 6 N.m Figure 2 Stress Analysis Figure 3 Deformation Analysis Figure 4 Strain Analysis Step 5: Chain link analysis: 6 N.m, F = 357.4 N, smaller sprocket = 35 mm Figure 5 Stress Analysis Figure 6 Deformation Analysis Figure 7 Strain Analysis http://www.iaeme.com/ijciet/index.asp 205 editor@iaeme.com
Timur Choban Khidir 6. CONCLUSIONS The main physical parameters of the design with reasonable assumptions have been determined through practical considerations. Cast alloy is used as the materials for both chains due to its high strength, toughness, and its economical effects and cast carbon steel used in Jack. Depending on the analysis of FEA, it shows that the max. nodal displacement value of the system of carjack is about.048e-00 mm as shown in Figure 8 and max. Von Mises 3.625e+008 shows in Figure 7, when max. load (9620 N) applied Furthermore, it seen that max. Von Mises stress, max. safe point. And we tried this carjack on the vehicle (Kia Rio model 2005 its curb weight is 090 kg) practically to see wether it rasie the vehicle or not, we saw it is succeeded as seen in the figure 2-b. 7. RECOMMENDATIONS In this model we currently used chain and sprocket set for transmission. In the future, maybe use the gears or special kind of hydraulic motor and work comparison between each type and choose the best type that transmits power and motion. REFERENCES [] Budyanas, G.R. and Nisbett, K.J., (2008), Shigley s Mechanical Engineering Design, McGraw-Hill Companies 8th Edition, pp 67 40, ISBN: 978 007 25763 3. [2] Khurmi, R.S. and Gupta, J.K. (2005), A Teaxt book of Machine Design, Eurasia Publication House (P.V.T) Ltd. 4th Edition, 230 pp. ISBN: 8 29 2537. [3] Lonon, E.M., East Orange, N.J. 992. Motorized Jack, US Patent No. 5085407. Date of patent. Feb 4, 992. AUTHOR DETAILS TIMUR CHOBAN KHIDIR B.Sc. University of Technology Baghdad / Mech. Eng. 2005 MsD. Gazi University (Ankara) / Turkey 200 Specialist: Applied Mechanic Lecturer in College of Engineering / Kirkuk University http://www.iaeme.com/ijciet/index.asp 206 editor@iaeme.com