Motorized lifting machine 2015

Abstract
During material handling, different problems arise and the material handling may not be
completed on time at a possible minimum energy consumption which in turn leads to
customer dissatisfaction and loss of profit. Having this in mind this study is conducted to
solve such problems. That means the objective of the study is to design Motorized lifting
machine, to simplify lifting heavy load, to increase the productivity by minimizing operation
time and to increase safety of the operation

To achieve this objective, the necessary information is collected through primary and
secondary data sources, the collected data is analyzed and presented using table, graphically
and Auto cad drawing.
Finally, we are interested to recommend about our design targeted to:
To increase the efficiency of the product & at minimum cost using the motorized lifting
machine gives many service for manufacturing company. designing of this lifting machine
that can be operate mechanically by rack and pinion mechanism to avoid hazards of
workers and to increase productivity, to achieve its target and satisfy its customers.

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Acknowledgment
Our thanks and appreciation goes to all who have helped us in the attainment of this project.
Above all, we would like to thank the Almighty GOD for giving us the courage to complete this
project. Next, we would like to extend our thanks to our advisor Mr.Tekuneh F. for his sharp and
valuable comments.
Next, we would like to extend our gratitude to all the mechanical engineering lecturers who
support by giving advice and motivation when we ask them and we would like hear felt thank to
our family for continuous effort by helping financially and moral to do this project.

Azmeraw Zelalem, Habtamu Abebe, Ataklti Niguse, Elias Wodajo

ITR/0177/03, ITR/0476/03, ITR/0157/03, ITR/0335/03

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Table of content

Contents Page
Abstract .......................................................................................................................... I

Acknowledgment ......................................................................................................... II

Table of content .......................................................................................................... III

List of Figures ............................................................................................................... V

List of table ................................................................................................................. VI

Acronyms ...................................................................................................................VII

Unit conversion factors .............................................................................................. IX

CHAPTER ONE: Introduction ...................................................................................1

1.1- Background of the project........................................................................................................................ 1

1.2- Problem of statement .............................................................................................................................. 2

1.3- Objective .................................................................................................................................................. 2

1.3.1- General objective .............................................................................................................................. 2

1.3.2- Specific objective .............................................................................................................................. 2

1.4- Expected results ....................................................................................................................................... 2

1.5- Scope of the project: ................................................................................................................................ 3

1.6- Significance of the study .......................................................................................................................... 3

1.7- Limitation of the project .......................................................................................................................... 3

1.8- Methodology of the study ........................................................................................................................ 3

CHAPTER TWO: Literature Review ........................................................................5

2.1- Introduction.............................................................................................................................................. 5

CHAPTER THREE: Design Analysis .....................................................................17

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3.1- Geometric analysis ................................................................................................................................. 17

3.2- Force analysis ......................................................................................................................................... 18

3.3-Design of spur gear ................................................................................................................................. 19

3.4- Design of Rack ........................................................................................................................................ 21

3.5- Design of Shaft ....................................................................................................................................... 22

3.6- Design of bearing.................................................................................................................................... 28

3.8- Design of bolt and nut ............................................................................................................................ 33

3.9- Design of carriage ................................................................................................................................... 35

3.10- Frame ................................................................................................................................................... 36

3.11- Design of Base plate ............................................................................................................................. 37

3.12- Working principle ................................................................................................................................. 44

3.13-Cost Analysis.......................................................................................................................................... 48

CHAPTER FOUR: CONCLUSION AND RECOMMENDATION ......................49

4.1- Conclusion .............................................................................................................................................. 49

4.2 -Recommendation ................................................................................................................................... 50

4.3- Reference ............................................................................................................................................... 51

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List of Figures

Fig 2.1 fork lift ...................................................................................................................................................... 6

Fig 2.2 power truck ................................................................................................................................................ 9
Fig 2.3 hoisting equipment[8] ............................................................................................................................. 11
Fig 2.4 terminology of gear ................................................................................................................................. 13
Fig 3.1 geometric analysis ................................................................................................................................... 17
Fig 3.3 teeth ........................................................................................................................................................ 20
Fig 3.4 spur gear ................................................................................................................................................. 21
Fig 3.6 moments .................................................................................................................................................. 26
Fig 3.7 bending moment ..................................................................................................................................... 27
Fig 3.9 bearing .................................................................................................................................................... 30
Fig 3.10 bevel gear .............................................................................................................................................. 33
Fig 3.11 bolt and nut ........................................................................................................................................... 35
Fig 3.12 carriage ................................................................................................................................................. 35
Fig 3.13 frame ..................................................................................................................................................... 37
Fig 3.14 plate ...................................................................................................................................................... 38
Fig 3.15 battery ................................................................................................................................................... 40
Fig 3.16 general assembling of lifting machine .................................................................................................. 43
Fig 3.17 general assembling of lifting machine .................................................................................................. 45

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List of table
Table 3.1 standard selection of shaft .................................................................................................................... 23
Table 3.2 bearing life ........................................................................................................................................... 29
Table 3.3 Principal dimensions static& dynamic load capacities ......................................................................... 29
Table 3.4 dimension of bolt and nut ..................................................................................................................... 34
Table 3.5 the possibility operation of four quadrants. ......................................................................................... 40
Table 3.6 part name ............................................................................................................................................. 44
Table 3.7 result .................................................................................................................................................... 46
Table 3.8 cost analysis ......................................................................................................................................... 48

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Acronyms

L=Length
h=Height
Zp=teeth of pinion
Dp=Diameter of pinion
Vi=Initial velocity
Vf=Final velocity
Vav=Average velocity
m=mass
a = acceleration
Ft=Tangential of tooth force
W =Load
m= Module
P=Power
Cs=Service factor
PE=potential energy
Pc=Circular pitch
Fn=Normal force
Fr=Resultant force
T=Torque
b=Face width
N=Speed
V=Velocity
c =Dynamic load rate of bearing
p=Applied radial load of the bearing
d=Width

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L = Slant height of pitch cone

Rm=Mean radius of driver gear

=Efficency

D.C=Direct current
H=Bolt head

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Unit conversion factors

1 ton = 1000K.g

1 m = 1000mm

1kw = 1000W

1 Mpa=1 N/mm2

1 rev = 2

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CHAPTER ONE: Introduction

1.1- Background of the project

Motorized lifting machine is a machine that used to lift heavy load or objects from
one place to the specific or desired place. this motorized lifting machine is one type
machine that have many advantage from those one to save time, reduced labor force,
increase the speed of the work and reduce the labor cost etc. part of this machine include
power transmitter shaft from the power source of the motor to pinion shaft, bevel gear,
spur gear, rack road, load carriage plat, nut and bolt.

A lifting device with the aid of control load carrying member, can lift and lower the
load vertically and also move it horizontally in one or more direction. The load carrying
member is a part of lifting device which directly sustain the load. The lifting
components or equipments loaded to the carrying plate. In connection with lift in
operations where representative of several an activities are involved one person shall be
placed change of planning and conducting the lifting operations. the work using lifting
device and lifting accessories shall be planed, organized and conducted in such way that
dangerous situation are avoided.
The mechanical strength and stability of lifting device and lifting accessories shall be
assured. Especially consideration shall, for example be paid to the loads which are to be
lifted and the load on suspension points. The modern in lifting machine was developed
in the 1920s. The lift machine has since became an indispensable of equipment in
manufacturing and ware housing operations the design of this lift machine should be
creative, simple and use minimum cost especially the material cost.
To improve the manual lifter machine has been developed the needs of small and
medium industries, which are normally man powered. In most of the company the loads
are lifted by using this lifter machine.
In order to avoid all such disadvantages, the motorized lifter machine has been
designed in such a way that it can be used to lift the load very smoothly without any
impact force. The operation is made simple so that even unskilled labor can use it with
ease.
The working area of the lifter machines are especially:
-cement factory
-sugar factory
-textile factory

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1.2- Problem of statement

In many companies motorized lifter machine was not commonly conducted rather
manual lifter machine was used to lift the objects by using human power.
This exposes the company to different problems like delay on meeting the due date,
elongated delivery time, wastes the time to lift the material which decrease the
efficiencies and productivity of the company , payee extra money for labors , less
customer satisfaction, less competitive in the market and finally loss of customers. This
shows there is a problem which needs an attention, and unless the company will suffer
with a loss.

1.3- Objective

1.3.1- General objective

The main objective of the study is to design motorized lifting machine that work
mechanically in order to reduce operation time, to reduce labor cost, to increase profit of
the company.

1.3.2- Specific objective

 Material selection
 Geometric analysis
 Force analysis of the machine
 Part design
 Cost analysis

1.4- Expected results

 The design has a good capacity of lifting operation.

 No need experienced worker.
 Design with parts that are easily repaired or replace.
 Easily operated.
 To be easily maintainable of machine.
 To provide its function up to five years by maintaining.
 To be simple in operation.
Generally, it is expected to be designed have faster, structurally durable and have well
economically

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1.5- Scope of the project:

This study mainly focuses on showing the way how to designing and analysis for in
modern that interfaces the users. This thesis will focus only in designing motorized lifter
machine.

The project aim how to feels users interest and addressed user hands-on all industry.
Our design parameters, design specification, and design objective are determining the
success of the project. To be successful in improving motorized lifter machine used to find
so many data searching different types of documents. The aim is to distribute motorized
lifter machine in everywhere who uses it.

1.6- Significance of the study

The significance of this study is to explore solutions to problems related to delay on

meeting the due date, elongated delivery time, wastes the time to lift the material which
decrease the efficiencies and productivity of the company, pay extra money for labors ,less
customer satisfaction, less competitive in the market and finally loss of customers.
Moreover, it tries to address the aforementioned problems by using motorized lifter
machine. In addition to thesis helps for organization (individuals) to accomplish tasks on
time at a possibly minimum cost, to increase its production efficiency& to provide better
services to its customer. The study is also valuable for further and better research.

1.7- Limitation of the project

Even if the project successfully accomplished there were a lot of limitation that can be
rendered as for doing it.
When we design our project the following limitations are faced:

 Willingness' of people.
 Lack of available resource
 Shortage of available data
 It doesn’t use the actual cost since it is so secret and not given to everyone

1.8- Methodology of the study

Methodology is a method that used how to do the project like data collection, data
presentation the study was conducted through gathering quantitative and qualitative
information about motorized lifter machine.

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Data collection: data collection process is a process that collects data from different
source these divided into primary and secondary
Data was collected from both primary and secondary source .

1. Primary data collection sources: it is a type of data collection that can be obtained
by observation, questionnaire and interview with concerned people. For example we
asked five persons those are workshop head, machine operator, managers,
technician, and foreman. This is held on by applying non probabilistic
judgmental/purposeful/ sampling to get the right information what we need.

2. Secondary data collection sources: As secondary data sources we use: mechanical

books, journals, internet access& Different Literatures on lifter machine are used to
construct the study.

Data presentation: after the data have been collected and organized they are ready for
presentation data by: graphically, table and Auto cad drawing.

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CHAPTER TWO: Literature Review

2.1- Introduction

A motorized lifting machine is a device that used to lifting a load from one place to the
desired place. Researches and experiments had been done manual lifting machine for a long
period of time. Many modifications had been done on manual lifting machine.

The nature of industries, manufacturing involved and types of design of a machine and a
plant in operational innumerable, constantly the varieties of materials lifting system. Used
in industry is also very large in number and diverse in concept and design. New equipments
are being designed and manufactured continuously. It is therefore, essentially to classify
such large number of material handling equipment in to a few basic types meaning full
discussion of those equipments. There have-been many attempts by statics in the field of
material handling to classified equipment in different ways. However, in the present book
classification based on the following equipment will be followed. These types of lifting
machine have many applications in industry to transport and lift materials or loads.[10]
There are many types of lifting machine among those are:

 Forklift truck.
 Power pallet truck.
 Crane machine.
 Hoisting equipment.

Forklift trucks also known as lift truck :

To lower or higher lifting machine, stacker-truck, or a side loader is a power industrial truck
used to lift and transport load or materials. The modern forklift truck was developed in
1920s by various companies including the transmission manufacturing company. The fork
lift truck has since become an indispensable piece of equipment in manufacturing and
warehousing operations.[10]

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Fig 2.1 fork lift

The history the lifter machines are begging in 1929, Hyster company is already built this
company is one of the earlier company that make the lift machine with the original machine
were steel and lumpier carries is a version of stand less truck that continued in production,
with upgrade of course.
The first actual lift machine is in 1935 based on reviewed tractor chases. The range was
broadened again with the Kerry crane. It use during world war two by American. The
begging in 1947, gough and hammer also started importing Hyster Ransomes Electric
forklifts. Formed after Hyster took over the British Ransoms company, Hyster Ransoms
become a popular addition to gough's product lineup. When Hyster started designing and

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manufacturing it's on electric forklifts in 1964, the ransomed name dies appeared. The first
Newzeeland Hyster, Ransoms customer Christchurch's D.H.Brown, who operated.
The forklift trucks are the backbone of industry around the line of the First World War,
machines were design with an electrical plate form that could be raised or lowered. The war
effort sprocket to other new innovations. Including a bomb-handling crane with power
lifting mechanism, consider to be the first electric lift truck.
Among the powered industrial vehicle/truck family most the versatile, useful and widely
used equipment is industrial lift truck property forklift truck. this are self loading counter
balanced, powered wheeled vehicles, with operator setting on the vehicle, design to raise,
move and lowered load on forks or other attachments fastened to mast which is fixed in
front of the vehicle to allow lifting and stacking of loads. Forklift trucks are used for
lifting, lowering, stacking, unstacking, loading and unloading and transporting of medium
to large weight, uniformed shaped unit loads, intermittently.
However, the limitations of this equipment are
I. Usually require of pallet container.
II. Require skilled operators.
III. Equipments need maintenance facilities.
IV. Capacity of this equipment varies from one ton to sixty ton.
V. Slow travel speed.
VI. Suitable for short hours,
Other factors of Fork lift truck are
 The source of power is petro or LP gas engine.
 The mast may be titled forwarded or backward within a range, for better
stability during movement.
 The mast may be a single mast or may be telescoping in design which
allows high lifting of the load for trucks that must run through limited head
room areas.
 In certain designs, the forks are independently retractable outboard and
inboard through pantograph mechanism. Loads are picked up and placed
while forks are outboard but are moved inboard for greater stability during
movement.
 The operation of the mast and movement of the forks (or any other
attachment) are through a hydraulic power pack.
 The body of the truck is purposely built heavy which act as counter load
while lifting loads on forks/attachments.
 Solid rubber tires are provided for operation in different floor conditions.
The rear two wheels are steered for manipulation of the forks/attachment fixed in front
of the truck. ‘Powered industrial trucks’ is a common term referring to forklifts, container-
handling trucks, reach-trucks, turret trucks and the like. Since their introduction forklifts
have been an integral ingredient for materials handling across a multitude of industries.

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Global injury/fatality data identifies forklifts as a prominent occupational hazard that has
occurred as a by-product of automation and bulk material handling. (Feare, 1999)
With the introduction of forklifts came a shift in plight of materials handling towards
adopting a bulk oriented approach. This derived jointly from the need to improve
productivity and to reduce the instance of workplace manual handling injuries. As a result, a
niche` market was created for specific plant and equipment to cater for such demand, but
also unfortunately released a new ream of hazards to the workplace.
A lack of consideration of the interface between pedestrian workers and forklifts in the
workplace has resulted in forklifts comprising many of the more serious injuries and
fatalities in the workplace. These effects have been felt throughout industries ranging from
manufacturing to retail environments, and require an array of engineering and
administrative interventions to combat the exposed risks. These interventions should extend
from the current hygiene and ergonomic focus and look towards integrating automated
logistics planning, with on-board intelligent vehicle technology. (Janicak, 1999)
In Australia during the period 1989-1992, there were 52 forklift related fatalities, with most
of these fatalities occurring as the result of persons being hit by falling objects (40%)
(NOHSC, 1998). Recent data for Victoria indicates that this trend has only changed
marginally, with around 500 claims and 2 fatalities reported annually between 1993-1997
(VWA, 1999).
The corresponding data in the USA identifies that nearly 100 forklift related fatalities are
recorded annually (94 in 1995), which most often resulted from forklift rollovers (25%)
(BLS, 1997&1998). Such is the profile of forklift safety in the USA, for powered industrial
trucks (inclusive of forklifts) as a means of trying to stem the flow of incidents from forklift
related operations. At least two provinces in Canada have also identified the occupational
hazard, which forklift operation poses. In Ontario 18 fatalities were recorded for the period
1990-1995 (MOL, 1999), whilst the Workers’ Compensation Board in British Columbia
reported 3 fatalities in 1997 bearing great similarity to the data reported here in Victoria
(WCBBC, 1998). [10]

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Power Truck:
When a vehicle /truck contains its own source of motivate power it is called power truck.
Power trucks are divided into several categories of equipment. [8]

Fig 2.2 power truck

The wide Varity of powered industrial truck have been classified into the following groups.

a) Mode of action (fixed pallet form truck).

b) Plate form lifts truck.
c) Pallet lifts truck.
d) Walkie truck.
e) Straddle carrier.

a) Fixed Platform Truck (powered)

These are powered (battery, diesel or gas operated) industrial trucks having a fixed level, no
elevating platform for carrying load. Materials to be moved have to be loaded and unloaded
to and from the platform by hand, hoist or carne. Capacities of these trucks can go up to 40
tons. Smaller capacity models are called load carriers. Operator normally stands on the
truck and runs it. Platform trucks are particularly useful for occasional handling of heavy
loads.
b) Platform Lift Truck (powered)

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These equipments are a particular type of powered platform truck, whose platform can be
raised and lowered to handle loads on skids. Range of lift of the platform may be ‘‘low-
lift’’, up to 300 mm or ‘‘high-lift’’, over 300 mm.
c) Pallet Lift Truck (powered)
These are similar to platform lift truck in which the platform is replaced by forks to work
also with loads on pallets. These are basically for number of fork-lift trucks

d) Walkie Truck
This term implies different types of powered trucks described above, when the operator
walks with the truck and operates it by means of controls available on the truck handle.
Willkie trucks are smaller, lighter and slower than rider-types, generally powered by
battery.
These are designed to fill the gap between hand trucks and powered rider-trucks in which
the operator stands/sits on the truck.
e) Straddle Carrier
This is a self-loading powered truck for movement of long and heavy loads including
shipping containers. The truck consists of an inverted “U” shaped frame having wheels
mounted on outside of the frame. The truck can straddle a load / loads, picks it up with
hydraulically operated load carrying shoes, mounted inside the frame, and then move with
the load and unload it very quickly at a desired location
Crane:

Crane is material handling equipment for lifting or lowering a load by hook and moving
(transferring) it horizontally, in which the hoisting mechanism is an integral part of
equipment. A crane may be driven manual or by power and may be fixed or movable. A
crane essentially consists of one steel structure to hoisting mechanism or a winch
mechanism with its pulley and pulley system. Suitable load handling attachments and drive
and control. The major classification of crane is based on whether there are stationary or
mobile. However, it is to be noted that, even for the stationary cranes, some structural
component of the crane is capable of movement for transferring the load within reach of its
movement. Movements of components of these stationary cranes may be linear, revolving
or combination of both.

Revolving cranes: The characteristic feature of these cranes is presence of a structural arm
Called boom, which can be rotated through 360° about a vertical axis. These cranes are also
called rotary crane or slewing crane. Boom may be strut or stress type. The lower end of the
boom is affixed to a mast, base, carriage or support against which it can be pivoted and
moved up and down which called lifting or booming is. The upper end of the boom
supports a hook or other end attachments for lifting of load. Different types of cranes are
grouped under this classification. Mechanism employed for rotating the boom is called

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slewing mechanism. Usually three different types of slewing mechanisms are used which
are:
(i) Crane superstructure revolves together with the pillar or column which is mounted on
bearings. Jib cranes generally fall under this category.
(ii) The boom rotates about a pillar fixed on a foundation or in the crane truck.
(iii) The entire crane superstructure is mounted on turntable which rotates about and
secured to its non revolving part. The turntable of the crane rests on a number of rollers
running or circular rail erected on the foundation or on the crane truck. Rack and pinion or
cogwheel
Drives are generally employed for rotating the turntable.(8)
Hoisting equipment:

Hoist is an apparatus for raising or lowering a load suspended from a hook on the end of a
chain or wire rope. A hoist may be fixed i.e., stationary, base mounted or supported from
overhead by a clevis or hook. It may be travelling type mounted on a track. Hoists are
rugged, dependable, simple to operate and inexpensive. Their installation is easy.

Fig 2.3 hoisting equipment[8]

Hoists are truly the basic hoisting equipment. These are extensively used in manufacturing
industry, workshop, truck terminal, and construction & erection site and even in small
garage for handling relatively light loads. These are used for loading and unloading of
varying jobs from machines, transfer of loads between work places. Hoists supplement
overhead travelling cranes, when put on a monorail.
Limitations of hoists are that they are used for relatively lighter loads, they are relatively
slow, have limited travel distance and fixed direction determined by the track. The
components of this motorized lifting machine are shaft, bevel gear, spur gear, rack, bolt and
nut, carriage, bearing frame and plate.[8]

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. Gears: are defined as tooth wheel or multi lobed cams, which transmit power and
motion from one shaft to another by means of successive engagement of teeth. Gear drives
have the following advantages compared with chain or belt drives
i. It is positive drives and the velocity ratio remains constant
ii. The centre distance between the shafts is relatively small
iii. It transmit very large power than belt or chain drives
iv. The efficiency of gear drives is very high even up to 99% in case of spur gears
v. It can transmit motion at very low velocity which is not possible with belt drives

Classification of gears:

Gears are broadly classified into four spur, helical, bevel and worm gears.
spur gear: are recommended when the teeth are cut parallel to the axis of the shaft as the
teeth are parallel to the axis of the shaft spur gear are used only when the shafts are
parallel.
Helical gear: the axis of the shaft is perpendicular to the tooth.
Bevel gear : when the axis of the shaft are at right angles to each tooth.
Worm gear drives: are used for shafts the axis which do not intersect and perpendicular
to each other.

Selection of type of gear :

The first step in design of gear drive is the selection of proper type of gear for a give
application. the factor that are consider for deciding the type of gear are general layout of
the shaft, speed reduction, power to transmit, input speed and cost. Spur gear is used when
the axis of the shaft are parallel to the tooth.[1]

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Fig 2.4 terminology of gear

The pitch circle is a theoretical pitch diameter. The pitch circles of a pair of mating gears
are tangent to each other. A pinion is the smaller of two mating gears. The larger is often
called the gear.
The circular pitch p is the distance, measured on the pitch circle, from a point on tooth to a
corresponding point on an adjacent tooth. Thus the circular pitch is equal to the sum of the
tooth thickness and the width of space.
The module m is the ratio of the pitch diameter to the number of teeth. The customary
unit of length used is the millimeter. The module is the index of tooth size in SI.
The diametrical pitch p is the ratio of the number of teeth on the gear to the pitch diameter.
Thus, it is the reciprocal of the module. Since diametrical pitch is used only with U.S. units,
it is expressed as teeth per inch.
The addendum d is the radial distance between the top land and the pitch circle.
The dedendum b is the radial distance from the bottom land to the pitch circle. The whole
depth ht is the sum of the addendum and the dedendum.
The clearance circle is a circle that is tangent to the addendum circle of the mating Gear.
The clearance c is the amount by which the dedendum in a given gear exceeds the
addendum of its mating gear. The backlash is the amount by which the width of a tooth
space exceeds the thickness of the engaging tooth measured on the pitch circles.
Pressure angle it is the angle between normal to two gears teeth at the point of contact and
the common tangent at the pitch point. It is usually denoted by Φ. the standard pressure
angle 14.5o and 20o.

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A gear rack: is mesh with the super gear, but the mechanism is liner. Gear rack consists
of teeth equally spaced along a straight line. A pinion is placed on the side of the rack. The
rack converts the rotary motion of the pinion in to linear motion.

Shaft: is a rotating machine element which used to transmit power from one place to
another place. The power is delivers to the shaft by some tangential force and the resultant
torque (twisting moment) set up within the shaft permits. The power to be transferred to
various machine linked up to the shaft. In order to transfer the power from one shaft to
another, the various members such as pulleys and gears are mounted on it. This member
along with the force extorted upon them causes to bending. In other words we may say that
a shaft is used for the transmission of torque and bending moment a shaft is the component
of a mechanical device that transmits rotational motion and power. It is integral to any
mechanical system in which power is transmitted from a prime mover, such as an electric
motor or an engine, to other rotating parts of the system.
The material used for shaft should have the following properties

- It have should have high strength

- It should have good machinability
- It should have low notch sensitivity factor
- It should have good heat treatment properties
- It should have wear resistance

Type of shaft:

The following two types of shaft are important from subject point of view.
1. Transmission shaft: - these shafts transmit power between the source and the
machine absorbing power since this shaft carries machine parts such as pulleys,
gears etc. Therefore they are subjected to bending in addition to twisting.
2. Machine shaft: - the shaft from an integral part of the machine itself. The crank shaft
is an example of machine shaft.
From the above type of shaft, select transmit shaft. Due to the design needs to
transmit power from one component to another component of the machine.
Generally shafts may be designed on the basis of
- Strength
- Rigidity and stiffness
In designing shaft on the basis of strength the following case be consider
i. Shafts are subjected to twisting moment (Tongue) only
ii. Shafts are subjected to bending moment only
iii. Shafts are subjected to combined twisting and bending moment.

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Bearing: are machine elements intended to support axles and shafts. They take up the
radial and axial loads impose on the shaft or axle they carry and transmit them to the casing
or machine frame. Bearing must also fix the shaft in the axial direction and enable it to
rotate about the specified geometrical axis.
There are two types of bearing those are:-
1. Rolling contact bearing and
2. Sliding contact bearing
Sliding contact bearing starts from rest with practically metal to metal contact and has high
coefficient of friction and rolling contact bearing has low starting friction due to low
friction offered by rolling contact bearing.
We select rolling contact bearing due to the following reasons.
a. Low starting and a running friction.
b. Ability to with stand momentary shock loads.
c. Accuracy of shaft alignment.
d. Low cost of maintenance as no lubrication required while in service.
e. Small over all dimensions.
f. Clean lines.
1- Ball bearing.
a. Deep groove bearing
b. Angular contact bearing (AC)
2- Roller bearings are:
a. Cylindrical bearings
b. Needle bearings
c. Taper bearings
d. Spherical bearings
For design proposed we select deep groove bearing because load capacity by the number
of balls and primarily designed to support radial loads, the thrust load capacity is about 70%
of the radial load.[2]
Bevel gears: are used to transmit power between two intersecting shafts. There are two
common types of bevel gears, those are straight and spiral bevel gear. The elements of teeth
of the straight bevel gears are straight lines, which converge in to a common apex point.
The elements the teeth of spiral bevel gears are spiral curve, which also converge in to a
common apex point.
Due to the following properties, select straight bevel gears

I. They are easy to design and manufacture.

II. Have good service life and have less friction.
III. High strength.
Bevel gears: for right angle drives, crossed helical gears or a worm set can be used. For
any angle between the shafts, including, bevel gears may be a solution. Just spur gears

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based on rolling cylinders, bevel gears are based on rolling cones. The angle between the
axis of the cones and the included angles of angles can be any compatible values as long as
the pieces of intersect. If they did not intersect, there would be a mismatch of a velocity at
the interface. If the teeth are parallel to the axis of the gear, it will be a straight bevel gear
and if the teeth are angled with respect to the axis, it will be spiral bevel gear.

A bolt and nut: are fastening device used to hold, clamp two parts together. There are
used to a separable joint of two or more parts. Those are held together by means of threaded
fastening, such as bolt and nut. Thread joint are used to hold two or more machine parts
together, these parts can be dismantled if required without any damage to machine parts or
fastening. Therefore, thread joint are detachable joint, unlike weld joint. [3]

The body of the bolt called shank. Nuts in general are square or hexagonal in shape. The
nuts with internal threads engage with corresponding size of the external threads of the bolt.

For nuts hexagonal shape is preferred to the square one, as it is easy to tightening even in
a limited space. This is because with only one -sixth of a turn. However, square nuts are
used when frequent losing a tightening is required.
There are three parts of thread fastening wiz a bolt or screw, a nut and washer.

A bolt is a fastener with head and straight threaded shank an intended to be used a nut to
clamp two or more parts.
A washer is thin annular shaped metallic disc. The functions of washer are as follows

 It distributes the load over the large area on the surface clamped parts.
 It prevents marring of clamped parts during assembly.
 It prevents marring of bolt head and nut surface.
Carriage: is one component of lifting machine that used to carrying the material or the
loads. It joins with rack by welding

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CHAPTER THREE: Design Analysis

3.1- Geometric analysis

1850mm

1700mm

L=1400mm
Fig 3.1 geometric analysis

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3.2- Force analysis

Ftb

Fb Fb
Fig 3.3 force analysis
In rack and pinion mechanism to find the tangential force we analysis the following:-

Specification of the design

 Total length of the machine (L) =1400mm
 Maximum height of the machine (max.h) =1800mm
 Maximum load travel height (h) = 1700mm
 Maximum load (W) =0.2ton =200kg =1962N
From the table value according to the type of service (that means the working condition is
light shock.
Distance = average velocity
= , t=
S=( ) ), S= ( , since the initial velocity (vi)=0
Then Vf =
S=h, h=maximum lifting height =1700mm from design specification.
a=g =9.81m/s2, vf = = =5.77m/s
a= ( ), t= ( ) , =0. 6sec
Potential energy (PE) =mgh = 200k.g = 3335J
Where m = mass, h = height
Power (p) = = = 5.5Kw
Then v= = =2.8m/sec
Ft = , where, Ft=tangential force
P=power, cs=service factor from table=1.54
Ft= =

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3.3-Design of spur gear

Material selection of spur gear:

Spur gears formerly were the type most commonly used in industry due to their simple
manufacturing and reduced cost—a consequence of the alignment of the teeth with the axis
of rotation. The profile of the tooth is designed to maintain constant ratio from one gear to
the other gear. This keeps the tangential velocity from the pinion equal to the gear, ensuring
a smooth and quiet operation.

In our design we use spur gear to transmit motion form rotary to linear. The material used
for to manufacture gears depends up on the strength and the service conditions. The gears
may be manifested from metallic or non metallic materials. The metal gears with cut teeth
are commercially obtainable in cast iron, steel and bronze we select cast iron for spur gear
design because it has high wear resistance strength stiffness and minimum cost.

Material selection of load carriage plates :

In our project we select rectangular plates that used to as a fixed coin and also sliding in
to affixed plate. Grey cast iron is the best material to prepare plate because that have high
compressive resistance high weld ability high wear resistance stiffness and minimum cost
. Material selection of Bolt and nut:

Is a type of fastener that used to connect motor to plate and guide rail to frame stand. The
selected material is plain Carbon steel most widely used kind of steel. Even if there are
three types depending on their carbon content; Medium carbon steel has carbon content
ranging from 0.25 to 0.70% (improves in the mach inability by heat treatment. It must also
be noted that this steel is especially adaptable for machining or forging and where surface
hardness is desirable.

 Tensile strength =600 MNm-2

 Young’s modulus =200 GNm-2
Generally many scholars say lifting machine is the simplest and easiest ways of lifting
loads. But in our design among different types of lifting machines we select motorized
lifting machine.

You should prove for yourself the validity of the following useful relations:

 =
 m=
 m

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Where P = diameter of pitch, teeth per millimeter

Z=number of teeth
M=module in millimeter
PC=circular pitch

Where D=diameter of the spur gear = 120mm

Z=number of teeth for spur gear =24

Fig 3.3 teeth

Where; Ft=Tangential force

Fn=normal force
Fr=resultant force
Pressure angle = 200
Fn=Ft/cos20o
Fr=Fn*sin20o
Fn = Ft/cos20o = 3025/cos20o = 3219N
Fr = 3219*sin20o = 1101N

T=Ft =3025N 0.06 =181.5Nm

Where Ft=tangential tooth load from the force analysis.

r=d/2=120mm/2=60mm=0.06m

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From standard table proportion of gear system at 20o full depth involutes

Addendum = m 1= 5 1= 5,

Dedendum = 1.25 = 1.25 = 6.25

Tooth thickness = 1.57 = 7.85

Minimum clearance = 0.25 m = 0.25 = 1.25

Face width = 10 m = 10 = 50
Where m = module, m = 5, all units are in mm.

Fig 3.4 spur gear

3.4- Design of Rack

Material selection of rack rod :

We select grey cast iron for rack rod because it has:

 High strength compressive resistance

 High carrion resistance high wear resistance
 Minimum cost

To determine the circular pitch of rack, Since two gears are mesh each other then module
and circular pitch are the same (i.e. module of pinion = module of rack =5, and circular
pitch of pinion = Pc of rack = 16mm).

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The length of the rack = 1700mm from design specification

Number of tooth on the rack (Z) = length of rack/linear pitch since incase of rack there is
linear motion is equal to linear pitch = 16mm
Then Z = L/Pc = 1700/16 = 106

Fig 3.5 rack

3.5- Design of Shaft

Material selection of shaft :

A shaft is component device that transmits rotational motion and power. It is integral to
any mechanical system in which power is transmitted from a prime mover, such as an
electric motor or an engine, tooth rotating parts of the system.
Shaft is a rotating machine element which used to transmit power for one place to another
the power is delivered to the shaft by some tangential force and a resultant torque (twisting
moment) set up within the shaft permits the power to be transferred to various machines
linked up to the shaft.

In order to transfer the power from one shaft to another the various members such as
pulley gears, bearing etc. are mounted on it. The shaft is rotating member usually circular

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cross section, used to transmit power or motion. It provides the axis of rotation or
oscillation of elements such s gears, pulley, key, wheels, crank, sprockets etc

Material used for shaft: the material used for shafts should have the following
properties
- It should have high strength
- It should have good machinability
- It should have low notch sensitiveness factor
- It should have good heat treatment property
- It should have high wear resistance property

Due to the above properties to select carbon steel or grade 40C8, 50C4, 45C8 and 50C12
it is an alloy of iron and carbon; from that grad we select 40C8 with carbon content up to a
maximum of 1.5%. The carbon occurs in the form of iron carbide, because of its ability to
increase the hardness and strength of the steel. Other elements e.g. silicon, sulphur,
phosphorus and manganese are also present to greater or lesser amount to impart certain
desired properties to it. Most of the steel produced now-a-days is plain carbon steel or
simply carbon steel. Carbon steel is defined as steel which has its properties mainly due to
its carbon content and does not contain more than 0.5% of silicon and 1.5% of manganese.
The plain carbon steels varying from 0.06% carbon to 1.5% carbon are divided into the
following types depending upon the carbon content.
1. Dead mild steel — up to 0.15% carbon
2. Low carbon or mild steel — 0.15% to 0.45% carbon
3. Medium carbon steel — 0.45% to 0.8% carbon
4. High carbon steel — 0.8% to 1.5% carbon

Standard sizes of transition shaft one 25 mm to 60mm with 5mm steps, 60mm to 110mm
with 10mm steps 110 to 140 mm with 19 mm steps and 140mm to 500mm with 20 mm step

Table 3.1 standard selection of shaft

Indian standard designation Ultimate tensile strength map Yield strength mpa
40C8 560 – 670 320
45C8 610 – 700 350
50C4 640 – 760 370
50C12 700min 390

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Mechanical properties of steel used for shaft

From our material selection of the shaft we select carbon steel of the grade 40C8 that
means the ultimate tensile strength the interval from 560-670 Mpa and also yield strength
320Mpa.
The following stresses are induced in the shafts

1. Shear stresses due to the transmission of torque (I.e. due to torsion load )
2. Bending stress (tensile or compressive) due to the force acting up on machine
elements. Like gear, pulley and etc. As well as due to the weight at the shaft itself
3. Stress due to combined original and bending loads.
The ASME code for the design of transmission shafts, the maximum permissible working
stresses in tension or compression may be taken as
a) 112 Mpa for shafts without allowance for key ways
b) 84 Mpa for shafts with allowance for key ways

Then the permissible tensile stress σt=0.6σet or σu

The maximum permissible shear stress must be taken as

a) 96 Mpa for a shafts without allowance for key ways

b) 42 Mpa for a shaft with allowance for key ways and the permissible shear stress.

τ=0.3σer or o.18σu which is less

The shaft may be designed on the basis of

a) Strength
b) Rigidity and stiffness

In designing shafts on the basis at strength the following case may be considered.

i. Shafts subjected to bending moment only

ii. Shafts subjected or twisting moments or torque only
iii. Shafts subjected to combined twisting and bending moment
iv. Shafts subjected to axial loads in addition to combined torsional and bending
loads

Shaft design procedure:

Because of the simultaneous occurrence of torsional shear and normal stresses due to
bending, the stress analysis of a shaft virtually always involves the use of a combined stress
approach. The recommended approach for shaft design and analysis is the distortion energy
theory of failure. Vertical shear stresses and direct normal stresses due to axial loads may

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also occur. On very short shafts or on portions of shafts where no bending or torsion occurs
such stresses may be dominant.

1. Determine the rotational speed of the shaft.

2. Determine the power or the torque to be transmitted by the shaft.
3. Determine the design of the power-transmitting components or other devices that
will be mounted on the shaft, and specify the required location of each device.
4. Specify the location of bearings to support the shaft. Normally only two bearings are
used to support a shaft. The reactions on bearings supporting radial loads are
assumed to act at the midpoint of the bearings. Bearings should be placed on either
side of the power-transmitting elements if possible to provide stable support for
the shaft and to produce reasonably well-balanced loading of the bearings.
5. Propose the general form of the geometry for the shaft, considering how each
element on the shaft will be held in position axially and how power transmission
from each element to the shaft is to take place.
6. Determine the magnitude of torque that the shaft sees at all points. It is
recommended that a torque diagram be prepared.
7. Determine the forces that are exerted on the shaft.
8. Solve for the reactions on all support bearings in each plane.
9. Produce the complete shearing force and bending moment diagrams to determine
the distribution of bending moment.
10. Select the material from which the shaft will be made, and specify its condition.
11. Specify the final dimensions for each point on the shaft.

To find:

 Speed(N), N = = = 290rpm
 Torque (T), the torque of the shaft is the same with pinion gear, T=181.5Nm.
 Moment

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Ftp = 3025N

500 mm 500 mm

RA RB

Fig 3.6 moments

To find the moment at each point

Moment at RA= since from force analysis Ft= =3025N

, Ft 500mm+RB 1000

3025 0.5+RB 1=0

RB = -1512N
Negative sign indicate Rb is anti clock wise direction

=RA+ RB -Ft =0
=RA+1512-3025
=RA-1510.6
RA=1512N

Bending moment at RB, RA 1000 - Ft 500 = 1512 1 - 3025 0.5 = 0

Bending moment at Ft, RA 500 = 1512 0.5 = 756Nm, bending moment at RA and RB
= 0 because of there is not have distance.

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Ftp=3025N

Fig 3.7 bending moment

, where Mb =max. Bending moment

I = moment of inertia, I =

Y = d/2

Bending stress= 0.6 =0.6*320=192Mpa

From the material selection grade 40C8 yield strength = 320Mpa

d= = =35mm

To find the maximum shear stress we use the combined equation that means bending
moment and torque.

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{ = [ ]

{ = [ ] =

=92N/mm2

Syt, from material selection, Syt = 320Mpa.

To calculate factor of safety

(f.s)= = =2

Fig 3.8 shaft

3.6- Design of bearing

Bearing life: number of revolution or hours operating at contact speed, required the
Failure criterion develops.
Rating life: design the number of revolution or hours of operation, at constant speed, in
such a way that 90% of the bearing tested (from the same group) will complete or exceed
before the first evidence of failure develops .this is known as L10 life.
Basic dynamic load rating: contact radial load that a group of bearing can carry for L10 life.
L10 = (c/p)
Where L10 = bearing life
K is constant =3 for ball bearing and
k =10/3 for roller bearing
p =applied radial load
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C =dynamic load rate

Selection of bearing:

Table 3.2 bearing life

ssMachine used intermittently such as lifting
tackle, hand tool and house hold appliance 4000-8000hrs
Machine used 8 hrs of service per day such as
electric motor and gear drive 12000-20000hrs
Machine used for continues operation 24hrs per
a day such as pump, compressor and conveyor.
40000-60000hrs

Table 3.3 Principal dimensions static& dynamic load capacities

D D B C Co Designation
35 47 7 4030 3000 61807
62 9 12400 6950 16007
62 14 15900 8500 6007

Where d=inner diameter in mm, D=outer diameter , B=width

C=dynamic load capacities, CO=static load capacities in N

L10 = 60 n L10h/106 where L10h = rated bearing life in hours from table

N = speed of the shaft = 290rpm

L10 = 60 290rpm 4000/106 = 69.6 million revolution

L10 = (c/p) k , c = p (L10)1/k = 3024 (69.6)1/3 = 12439N

Where p = bearing forces, p = RA+RB = 1512+1512 = 3024N

From dimension static and dynamic capacities of single row deep grove ball bearing table
designation bearing number 16007 i.e.(C=12400N) is suitable for shaft diameter of 35mm
the difference between expected and actual dynamic load capacities(12439-12400=39N) is
consider to be negligible.
Where c = dynamic load from table bearing designation 16007,
Inner diameter (d) = 35mm
Outer diameter (D) = 62mm and width (B) = 9mm

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Fig 3.9 bearing

Material selection of bevel gear:

In bevel gears, the teeth are formed on conical surfaces and are used for transmitting
power between intersecting shafts. Two bevel gears in mesh are known as bevel gearing. In
bevel gearing, the pitch cone angles of the pinion and gear are to be determined from the
shaft angle, i.e., the angle between the intersecting shafts.
The selected material for the bevel gear is grey cast iron (grade FG150) because the
properties of grey cast iron have:
 It can be easily machined
 High compressive strength
 Low cost
 Wear resistance
The cast iron is obtained by re-melting pig iron with coke and limestone in a furnace known
as cupola. It is primarily an alloy of iron and carbon. The carbon content in cast iron varies
from 1.7 percent to 4.5 percent.

 Tensile strength = 100 to 200 MPa

 Compressive strength = 400 to 1000 MPa
 Shear strength = 120 M Pa
1MPa = 1MN/m2 = 1 × 106 N/m2 = 1 N/mm2
Teeth would be added to their circumferences in the same way that we add teeth to rolling
cylinders for circular gears. The teeth then act to guarantee no slip.

Velocity ratio (V.R) = = =

Where, DG = diameter of the driven gear

DP = diameter of the driver gear
TG = tooth of the driven gear

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Table 3.4 dimension of bolt and nut

Nominal major Pitch(p) Tensile stress Minor diameter
diameter(d) area at mm2 area are mm2
20 2.5 245 222

The minor diameter (dr) = d-1.226869p and pitch diameter (dp) = d-0.649519p
Where p is pitch, p=2.5mm from table.
d= 20mm
Lt = 2d+6 L ≤ 125 d ≤ 48 from table 8-1

M20 = 20mm, then Lt = 2*2+6 = 46mm

dp = d - 0.649519p = 20 - 0.649519 2.5 = 18.4mm.

dr = d - 1.226869p = 20 - 1.226869 2.5 = 16.93mm.

The total length of bolts and nuts take as 70mm (L). Lt = 46mm from the previous
calculation and the thickness of the metal = 10mm. unthreaded length of nut with washer
(Ld) = material thickness that means 10mm.

L = Ld + Lt + H where H is bolt head. Then H = L - Ld - Lt, H = 70 - 10 - 46

=14mm
Stress due to external force:

The following stresses are induced in a bolt when it is subjected to an external load.

a) Tensile stress: the bolts, studs and screws usually carry a load in the direction of the
bolt axis which induced tensile stress in the bolt.
Let dr = root or core diameter of the thread and
σt = permissible tensile stress for bolt materials. σt = 600Mpa from the material
selection. And dr = 16.93mm from the above calculation.
The external load applied (p) = (dr) 2σt/4 = 3.14 (16.93)2 600/4 = 135kN
If the external load is taken up by a number of bolts, then p = dr2 σt n
Where n = number of bolts.
We use eight bolts for this project. p = 135kN 8 = 1080kN.
b) Shear stresses: sometimes the bolts are used to prevent the relative movement of two
or more parts, and then the shear stress is induced in the bolt. The shear stresses
should be avoided as far as possible. it should be noted that when the bolts are
subjected to direct shearing loads, they should be located in such a way that the
shearing load come up on the body(i.e. shank ) of bolt and nut up on the thread
portion.

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When a number of bolts are used to share the shearing load, the finished bolt should
be fitted to remanded holes. Let d = major diameter of the bolt and n = number of
bolts. Therefore, shearing load carried by the bolt (Ps) = d2 τ n/4
Where τ = 0.5σt = 0.5 600Mpa = 300Mpa.
Ps = 202 300 8 = 753.6kN.

Fig 3.11 bolt and nut

3.9- Design of carriage

The shape of the carriage look likes rectangular in shape. The carriage have the following
dimensions: length (L) = 700mm and width (W) = 550mm

Fig 3.12 carriage

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Stress of the carriage :

When some external system of forces or loads act on a body, the internal forces (equal
and opposite) are set up at various section of the body, which resisting the external forces
this internal forces per unit area t any section of the body is known as unit stress or simply
stress. It denoted by sigma (σ) mathematically σ = F/A.
Where F = load or force acting on the body
A = cross sectional area of the carriage
A=L = 700
Then, 0.0051Mpa

3.10- Frame

The machine is supported by frame these frames are connected by welding to make a
composite frame stricture suitable for all over the machine parts. The frame is made from
steel. It is the part of the machine that used to support the machine part. Its dimension
1000mm length, 1200mm height, and 1000mm width and the dimension of bare are 50mm
width, 50mm length. The main frame supports the weight of the machine. The total weight
carried by the main frame is:
 Weight of the DC motor.
 Total lifting load.

Due to supporting heavy loads we select high carbon steel because as the carbon contain
increase the hardness of material also increase. Steel have the following properties.
- High wear resistance
- High strength
- High heat resistance
- Carrying heavy load
-Tensile strength=600Mpa

To find shear stress ( =Force (F)/shear area (As), F=Fm+FL, where Fm=Motor Force
take weight of motor is 25k.g, Fm=25 9.881=245.25N
FL=Total lifting load=1962N.Then, F=2207.25N

As=L w=50mm 50=2500mm2.But, there are four bares to resist load,

Then As=4 2500mm2=10000mm2.

Therefore, =F/As=2207.25/10000=0.222Mpa

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Fig 3.13 frame

3.11- Design of Base plate

The lower bas plate is subjected to caring the force applied by balanced load. So, take the
load of balanced weight 170k.g, W = 170 . Then the balanced load applied
on the plate (W) =1666N.
Let, be the stress produced by the normal balance load.
Is the stress produced by shear force and
A, is the area of the plate.
= ,A=w w=width of the plate
=length of the plate,
But the length of the plate = total length of machine - thickness of the frame
= 1400mm-2(50) mm = 1300mm

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w = 1080mm, where width of the plate is equal to the machine

width, Area of the plate (A) =
= = 0.01N/
, = , where t=thickness of the plate=10mm.
=1400
Then to calculate =
The structural parts include all the supporting of the four corner of the plate. These plates
are subjected to carry the load applied by normal weight of balanced the load
applied=1666N. Material selection of the plate is carbon steel tensile strength (290Mpa) and
yield stress (170Mpa).
=0.5
= , take factor of safety = 3

= =28.33Mpa.
Permissible sheer force of the material is greater than the normal sheer force of the plate.
So, it is safe. The maximum bending moment of the plate = = 270.725Nm

Fig 3.14 plate

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 Welding joint

Welding is an effective method of making permanent joints between two or more metal
parts. Welding is a permanent joint which is obtained by the fusion of edge the two parts to
be joined together, with or without the application pressure and filer material. The heat
required for the fusion the material may be obtained by burning of gasses or by electric arc.
Cast iron, steel and its alloys, brass and copper are the metals that may be welded easily.
Production of leak proof joints that can withstand high pressures and temperatures are made
With Possible advanced welding technology. For this reason, welding is fast replacing
casting and forging wherever possible. When compared to riveting, welding is cheaper,
stronger and simpler to execute at site with considerable freedom in design. Hence, it is
widely used in ship building and structural fabrication in place of riveting.
Advantages of welding over other joint
 The welding joint provides maximum efficiency which is not possible in case of
riveted joint
 The welding structure is smooth in appearance , it looks pleasing
 Welding joint is stronger and cheapest in cost
 The processes of welding takes less time than others
 It is possible to weld any part the body at any point
Types of welding:

Gas tungsten arc welding, shielded metal arc welding, oxy-acetylene, plasma arc welding
and etc. from those types of welding we select shielded metal arc welding because of
welded part is covered to protect from damage and its low cost.

 Lubrication

Lubrication is defined as the application of lubricants between two surfaces that are in
contact and in relative motion to one another.
Function of lubrication:

 To reduce friction which consequently reduces the power required to

overcome the same.
 To reduce wear and tear between the rubbing surface.
 To cool the surface by caring away heat generated by friction.
 To carry away the particles of worn metals and carbon.
 To reduced the noise of the machine element in which the lubricant has been
applied.
 To reduced the corrosion and deposit.
Classification of lubricants:

a. Liquid
b. Semi-liquid

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c. Solid
From the above types of lubricants select liquid lubricant, the liquid lubricant used in
bearings and gears are mineral oils and synthetic oils. The mineral oils are the most
commonly used because of their cheapness and stability. The liquid lubricants are usually
preferred where they may be retained.
 Battery

Every mechanical moment that is accomplished by an electric motor. Electric machines

are a means of converting energy. Motors take electrical energy and produce mechanical
energy; with this very basic concept of direction and speed control. We can move the motor
clockwise and anticlockwise as a result lift can move in upward and downward direction
and we can vary the speed of a DC motor.

Fig 3.15 battery

When the switches A and B are closed and switches B and C open a positive voltage
applied across the motor. By opening switch A and D, closing switch B and C, this voltage
is reversed, allowing reverse operation of the motor.
The switches are turned ON in pairs, either high left and lower right, or lower left and
higher right, but never both switches on the same side.

Table 3.5 the possibility operation of four quadrants.

High side left High side right Lower side left Lower side right Quadrant
description
ON OFF OFF ON Motor rotate
clockwise
direction.
OFF ON ON OFF Motor rotate
Anticlockwi

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se direction.
ON ON OFF OFF Motor
brakes and
decelerate
OFF OFF ON ON Motor brakes
and
decelerates.

 DC motor

Almost every mechanical moment that we see around us is accomplished by an electric

motor. Electric machine are a means of converting energy. Motors take electrical energy
and produce mechanical energy. Electric motors are used to power hundreds of devices we
use in everyday life. Motors came in various sizes. Huge motors that can take load of 1000s
hour’s power are typically used in industry. Some examples of large motor application
include elevators, electric trains, hoists and heavy metal rolling mills. Examples of small
motor application include motor used in automobiles, robot, hand power tools and food
blenders.
Electric motors are broadly classified two different categories, DC (direct current) and AC
(alternating current) with in these categories are numerous types, each offering unique
abilities that suit them well for specific application. In most cases, regardless of type,
electric motor consists of a stator (stationary field) and a rotor (the rating field or armature)
and operates through the interaction of magnetic flux and electric current to produce
rotational speed and torque. DC motors are distinguished by their ability to operate from
direct current.

There are different kinds of DC motors, but they all works on the same principles. To
study their basic principles of operation and their characteristics, it's important to
understand motor characteristics, so we can choose the right one for our application
requirement.

Electromechanical energy conversion :

An electromechanical energy conversion device is essentially a medium of transfer

between an input side and output side. Three electric machine (DC, induction, and
synchronous) are used extensively for electromechanical energy conversion.

The electromechanical energy conversion occurs when there is a change in magnetic flux
linking a coil, associated with mechanical motion. The input is electrical energy (from the
supply source), and the input is mechanical energy (to the load).

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Mechanical
electrical electromechanical energy energy
energy conversion device
Source

Motor load
DC motor consists of one set of coil called armature winding inside another set of coils or
a set of permanent magnets called stator, Appling average to the coils produces a torque in
the armature resulting in motion.
Stator:

 The stator is a stationary outside of part of a motor.

 The stator of a permanent magnet dc motor composed of two or more permanent
magnet per pieces.
 The magnetic field can alternatively be created by an electro magnet. In this case
a dc coil (field winding) is wound around a magnetic material that forms part of
the stator.
Rotor :

 Rotor is the inner part which rotates.

 The rotor is composed of windings which connected to the external circuit
through a mechanical communicator.
 Both stator and rotor are made up of Ferro magnetic materials.
Winding: Winding is usually made up of cupper. There are two kinds of winding
1. Armature winding: the wining through which the voltage is applied or
induced. It is made up of series or parallel connection of coils.
2. Field winding: the wing through which a current is passed to produced
flux...
Bidirectional dc motor speed controller:

To control the speed of a DC motor both the clockwise and anticlockwise direction are
the range of control if from fully off to fully on in both direction. Normally, switches are
used to change the direction of rotation of a dc motor. Now we have two things to control
the motor direction switch as well as battery switch.

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Fig 3.16 general assembling of lifting machine

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Table 3.6 part name

10 Motor 1
9 Wheel 4
8 Handle 2
7 Carriage 1
6 Plate 2
5 Frame 3
4 Bevel gear 2
3 Spur gear 1
2 Rack gear 1
1 Shaft 1
No Part Name Qty

3.12- Working principle

The battery is used to drive the DC motor; the DC motor input shaft is connected to the
driver bevel gear. The power driven to the DC motor, it will run so that the driver bevel
gear also runs to slow down the speed of the DC motor. The driver bevel gear transmits
motion to the driven bevel gear and driven bevel gear connected to the shaft. Pinion and
rack mechanism mounted on the center of the shaft. The load moving when rack moves
upwards, so that the material lifts from the ground to desired place by pinion and rack
mechanism. The motor draws power supply from the battery. The lifting and lowering of
load is done by changing the direction of motor rotation. when switch one is turned on and
switch two is turned off the DC motor shaft is start rotating clockwise direction when the
power is supplied from the battery to DC motor so that the bevel gear of the motor shaft
also run in speed of DC motor. Then the powers translate from the motor shaft to pinion
shaft by using of bevel gear by slow down of speed. the pinion gear is mesh to the rack
gear, the rack move up by rotating of pinion shaft then the load carrying plate which jointed
on the rack by welding and lift up from the ground by the help of rack and pinion
mechanism, after the load carrying plate rich it’s maximum lifting height switch two turned
on and switch one turned off then the motor shaft start rotating anticlockwise direction and
the load carrying plate return to its original position.

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Motorized lifting machine 2015

Fig 3.17 general assembling of lifting machine

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 Result

After identifying the weaknesses of the current design, literature review is uses the basic
idea of the existing solution concepts. The proposed concepts re then generated according to
the problem and establishment of customer needs and specification so the challenge is to
design motorized lifting machine that fulfilling the target product specification. The
knowledge in mechanical system is crucially needed for generating the design concept.
The coverage of the design so many results are obtained. this are improvement of
production rate, reduction of number of operator, simplification of the operation and control
system, being safety related function, safety customer needs and so on.
The following are designed values were obtained for motorized lifting machine system.

Table 3.7 result

Parameter Results
Potential energy in(J) 3335
Velocity in (m/s) 5.77
Speed (m/s) 2.8
Output power (kw) 5.5
Tangential force in(N) 3025
Diameter of spur gear in(mm) 120
Circular pitch of spur gear in (mm) 16
Normal force of spur gear in (N) 3219
Resultant force of spur gear in (N) 1101
Torque of spur gear in (Nm) 181.5
Addendum of spur gear in (mm) 5
Dedendum of spur gear in (mm) 6.5
Teeth thickness of spur gear in 7.85
(mm)
Face width in (mm) 50
Number of teeth rack 106
Circular pitch of rack in (mm) 16
Speed of shaft in (rpm) 290
Torque of shaft (Nm) 181.5
Bending moment of shaft in(Nm) 756
Bending stress of shaft in (Mpa) 192
Diameter of shaft in (mm) 35
Max. shear stress of shaft in (Mpa) 92
Factor of safety 2

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Bearing life in (million revolution) 69.8

Diameter of driven gear in (mm) 190
Speed of motor 460
Velocity ratio of bevel gear 1.58
Pitch angle for driven gear (degree) 58
Pitch angle for driver gear in 32
(degree)
Frame shear stress (Mpa) 0.222
Slant height of bevel gear in (mm) 113
Tooth factor of driver gear 0.1
Face width in (mm) 28
Tangential load of driver gear in 2361
(Nm)
Mean radius of driver gear 53
Torque of the driver gear in (Nm) 125
Power of motor in (kw) 6.03
Efficiency of the machine (%) 91
Thickness of bevel gear in (mm) 8
Addendum of bevel gear in (mm) 5
Dedendum of bevel gear in (mm) 6
Normal force of bevel gear in (N) 2512
Resultant force of bevel gear in (N) 859
Threaded length of bolt and nut in 46
(mm)
Bolt head length in (mm) 14
Load applied on bolt and nut in 135
(KN)
Shearing load of bolt and nut in 753.6
(KN)
Area of carriage in ( ) 385000
Stress of carriage in (Mpa) 0.0051
Length of plate (mm) 1300
Area of plate in ( )
1404000
Stress of plate in (Mpa) 0.01
Shear of plate in (Mpa) 1400
Permissible shear force in (Mpa) 28.33
Max. bending moment (Nm) 270.73
s

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3.13-Cost Analysis

Table 3.8 cost analysis

To compare the cost of this motorized lifting machine with four labor worker payment,
the payment of one person is 1200 birr per month. and the total payment of four persons are
4800 birr per month, then in one year salary of labor worker equal to 57600.but the service
life of motorized lifting machine is estimated to five years. so, salary of four person is
5*57600=288000birr per 5year and to compare these two costs as we seen the above table
the total cost of motorized lifting machine without considering overhead cost is 9728 birr.

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CHAPTER FOUR: CONCLUSION AND RECOMMENDATION

4.1- Conclusion

To conclude, our design project is important to facilitate production and to increase safety
of the workers in companies. From this project we have gain more knowledge about lifting
machine. We design and analysis efficiently as much as possible effort added some thing
started from manual lifting machine known more about motorized lifting machine.
This lifting machine system is designed with high degree of lifting loads efficiently. It
also very safe operational and maintenance cost. The project design includes design
specification, material selection, part design, and cost analysis.
Generally this machine is use full for easily lifting loads, moving material from one place
to the desired place, minimize delay time and applicable for different manufacturing
factories. Therefore, we will advice the company should use mechanically operating
motorized lifting machines rather than labor worker lifting systems to save time, labor cost
and profitability of the company.

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4.2 -Recommendation

For the future this machine can be upgraded to more users friendly by adding the future
such as automatic lifting loads in to a desired place, automatic controlling system and
motorized lifting machine must be widely manufacture for Ethiopia.
Finally, we are interested to recommend about our design targeted to increase the
efficiency of the product using the motorized lifting machine gives many service for
manufacturing company design lifting machine that can be operate mechanically by rack
and pinion mechanism we recommend for factories use motorized lifting machine to
avoid hazards of labor workers and to increase production
.

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4.3- Reference

[1] R.S Khurmi, J.K Gupta. TEXT BOOK OF MACHINE DESIGN, Multi color
illustrative edition.

[2] V.B BhandarI, DESIGN OF MAHINE ELEMENTS. Second Edition, New Delhi,
Tata Ms Graw-Hill.

[3] Joseph E. Shigley and Charles Are. Mischke, MEHANICAL ENGINEERING

DESIGN, Sixth Edition, Mc Graw-Hill Higher Education, A Division Of Mc Graw-
Hill Companies.

[4] Donaid r. Aske Land and Pradeep P.Phule, THE SIENCE AND ENGINEERING
MATERIAL, Fourth Edition.

[5] Irving H.Sahmes, ENGINEERING MECHANICES STATICS AND DYNAMICS,

Fourth Edition.
[6] Er.R.K Rajput, STREANGTH OF MATERIALS (MECANICS OF SOLIDS).
[7] Dr.Rs Parmer WELDING ENGINEERING AND TECHNOLOGY
[8] Immer, J.R., MATERIALS HANDLING, MCGREW HILL
[9] Internet website:
[10] http://www.fork-truck.org.uk
[11] http://www.alibaba.com
[12]http://www.google.com

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