CONTENTS

CHAPTER

NO TITLE PAGE NO
Abstract
1 Introduction
2 Literature survey
3 Components and Description
4 Battery
5 Microcontroller Unit
6 D.C Motor
7 Block Diagram
8 Working principle
9 Factors determining choice of Materials
10 Advantages and Disadvantages
11 List of materials
12 Cost estimation
13 Conclusion

ABSTRACT

This project work titled “Three axis hydraulic modern trailer” has been conceived

having studied the difficulty in unloading the materials. Our survey in the regard in

several automobile garages, revealed the facts that mostly some difficult methods were

adopted in unloading the materials from the trailer.

 Now the project has mainly concentrated on this difficulty, and hence a suitable

arrangement has been designed. Such that the vehicles can be unloaded from the trailer

in three axes without application of any impact force. By pressing the Direction control

valve activated. The oil from the hydraulic oil is goes to the hydraulic cylinder through

valve. The ram of the hydraulic cylinder acts as a lifting the trailer cabin.

CHAPTER-1

INTRODUCTION

Automation can be achieved through computers, hydraulics, hydraulics, robotics,

etc., of these sources, hydraulics forms an attractive medium. Automation plays an

important role in automobile. Nowadays almost all the automobile vehicle is being
atomized in order to product the human being. The automobile vehicle is being atomized

for the following reasons.

 To achieve high safety

 To reduce man power

 To increase the efficiency of the vehicle

 To reduce the work load

 To reduce the fatigue of workers

 To high responsibility

 Less Maintenance cost

Objectives:

 To study the basic hydraulic mechanisms.

 To study of three axis mechanism.

 To study design of hydraulic system components.

 CHAPTER-2

LITERATURE SURVEY

HYDRAULIC SYSTEM:

In the development of the submarine from pre-war classes, many changes and

improvements have occurred. One of the outstanding differences is the large variety of

submarine devices which are now operated by hydraulic power. In early classes, there

was no hydraulic system, and power requirements were met by means of air or electricity.
Along with constantly improving submarine design has gone a constant extension and

diversification of the use of hydraulic power.

Comparative advantages of hydraulic power

Hydraulic systems possess numerous advantages over other systems of power

operation. They are light in weight; they are simple and extremely reliable, requiring a

minimum of attention and maintenance. Hydraulic controls are sensitive, and afford

precise controllability. Because of the low inertia of moving parts, they start and stop in

complete obedience to the desires of the operator, and their operation is positive.

Hydraulic systems are self-lubricated; consequently there is little wear or corrosion. Their

operation is not apt to be interrupted by salt spray or water. Finally, hydraulic units are

relatively quiet in operation, an important consideration when detection by the enemy

must be prevented.

Therefore, in spite of the presence of the two power sources just described,

hydraulic power makes its appearance on the submarine because of the fact that its

operational advantages, when weighed against the disadvantages enumerated for

electricity and air in the preceding paragraphs, fully justify the addition of this third

source of power to those available in the modern submarine.

FACTOR AIR ELECTRICITY HYDRAULICS

Reliability Poor Good Good
Weight Light Heavy Light
Installation Simple Simple Simple
Control Mechanism Valves Switches and solenoids Valves
Maintenance Constant attention necessary Difficult, requiring Simple
skilled personnel
Vulnerability High pressure bottle Good Safe; broken
dangerous; broken lines lines cause
cause failure and danger to failure
personnel and equipment
Response Slow for both starting and Rapid starting, slow Instant starting
stopping stopping and stopping
Controllability Poor Fair Good
Quietness of Poor Poor Good
Operation

Familiarity of hydraulic principles

For many centuries, man has utilized hydraulic principles to satisfy common,

everyday needs, Opening a faucet to fill a sink with water a practical application of

hydraulics. Water moves through a dam in accordance with well-known principles of

fluid motion. There are hydraulic principles that explain the action of fluids in motion and

others for fluids at rest.

We are chiefly concerned, however; with that branch of hydromechanics which is

called simply Hydraulics and is defined in engineering textbooks as the engineering

application of fluid mechanics. It includes the study of the behavior of enclosed liquids
under pressure, and the harnessing of the forces existing in fluids to do some practical

task such as steering a submarine or opening the outer door of a torpedo tube.

Examples of hydraulically operated equipment are familiar to all. Barber or dentist

chairs are raised and lowered hydraulically; so is an automobile when placed on a

hydraulic rack for a grease job. Stepping on the brake pedal in an automobile creates the

hydraulic power which stops the rotation of the four wheels and brings the car to a halt.

For an understanding of how a hydraulic system works, we must know the basic

principles, or laws, of hydraulics, that is, of confined liquids under pressure.

HYDRAULIC COMPONENTS AND DESCRIPTION

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

will suddenly shatter into a number of pieces, showing that:

Figure 1 Applied pressure is exerted equally in all

directions

Liquids are practically incompressible.

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

Figure 2 illustrates the application of these principles to a closed hydraulic system.

Two cylinders each are having a base whose area is 1 square inch, are connected by a

tube. The cylinders are filled with liquid to the level shown, and a piston with a base of

the same area (1 square inch) is placed on top of each column of liquid. Then a

downward force of 1 pound is applied to one of the pistons. Since this piston has an area

of 1 square inch, the pressure upon it is 1 pound per square inch; and since the other

piston is of equal area, the same pressure, 1 pound per square inch, will be imposed

upward upon it.

Figure 2 Transmission of equal pressures to equal areas

Multiple units

It is not necessary to confine our system to a single line from

the source of hydraulic power. Hydraulic power may be

transmitted in many directions to do multiple jobs.

 Let us connect one cylinder to four others as in Figure 3. Here we apply a force

against the piston in the large cylinder. The pressure from the large cylinder is transmitted

equally to each of the pistons in the other four cylinders.

Figure 3 multiple units from a single source of

power

This is actually the method of operation of an automobile hydraulic-brake system

(see Figure 4). The foot pressure on the brake pedal (1) depresses a piston (2) in the

master cylinder (3).

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

stored in preparation for the next braking operation.

Figure 4 Automobile hydraulic-brake system

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.

A simple hydraulic system

On the basis of the explanation of basic hydraulic principles just given, it is

possible to construct a simple, workable hydraulic system which will operate some

mechanical device. For example, such a system might open and close a door, and hold it

in either position for any desired interval.

Basic units of a hydraulic system

 Such a system is illustrated in Figure 5. It necessarily includes the following basic

equipment, which, in one form or another, will be found in every hydraulic system:

A reservoir, or supply tank, containing oil which is supplied to the system

as needed and into which the oil from the return line flows.

Figure 5. A simple
hydraulic system

A pump, which supplies the necessary working pressure.

A hydraulic cylinder, or actuating cylinder, which uses the hydraulic

energy developed in the pump to move the door.

A cut-out valve, by means of which the pressure in the actuating cylinder

may be maintained or released as desired.

A check valve, placed in the return line to permit fluid to move in only one

direction.

"Hydraulic lines," such as piping or hose, to connect the units to each

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.

Single Acting Hydraulic Cylinder:

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

fluid has an area of 2 square inches.

 The cut-out valve is hand-operated. When closed, it shuts off the line between the

actuating cylinder and the supply tank, preventing the oil under pressure in the cylinder

from escaping into the return line; when opened, it releases this pressure, allowing the

loading spring inside the cylinder to expand, and the oil in the cylinder to escape back

into the supply tank.

A power-driven hydraulic system

The door-operating system illustrated in Figure 5 is far simpler than is usually

found in actual service. It has the obvious disadvantage that instantaneous opening of the

door is not possible because pressure is built up slowly by hand pumping.

Units of a power-driven hydraulic system

Figure 7 illustrates a system in which a motor-driven pump is substituted for 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,

which are the same as in the first system.

 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.
 Figure 8. Double acting hydraulic system

The piston is locked in the desired position by

the hydraulic fluid, which enters either side of

the piston as required and remains there until

forced out. Since the flow of the fluid must be

directed to either of two sides, a valve, which selects the direction of flow, is

installed in the line. This is called a control valve. Control valves vary with the

specific application, but generally they are equipped with four ports. Two are

connected to the actuating cylinder at either side of the piston. A third port is the

pressure port and receives fluid from the pump. The fourth port returns surplus

fluid either back to the reservoir or elsewhere in the system.

The reciprocating pump

The simplest practical application of this principle is seen in the hand-operated

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

piston. The piston makes a close sliding fit within the cylinder, reducing leakage to a

minimum, since excessive leakage destroys the efficiency of a pump. Both the inlet and
 outlet ports are equipped with check valves which

permit the liquid to flow in one direction only, as shown

by the arrows.

Figure- Hand-operated reciprocating pump

Assume that the intake side of the pump is connected to a supply of liquid. When we

move the piston to the right, lower pressure is created in the chamber formed by the

piston.

Higher pressure on the fluid outside the chamber forces fluid in through the inlet

port and fills the chamber. Moving the handle forward in the opposite direction forces the

fluid out. A check valve at the inlet port prevents flow there and, since the fluid must find

an outlet somewhere, it is forced out through the discharge port.

The check valve at the discharge port prevents the entrance of fluid into the pump

on the subsequent suction stroke. The back-and-forth movement of the piston in the pump
is referred to as reciprocating motion and this type of pump is generally known as a

reciprocating-type piston pump. It may have a single piston or be multi-pistoned. It may

be hand-actuated or power-driven. The reciprocating piston principle is conceded to be

the most effective for developing high fluid pressures.

CHAPTER-3

COMPONENTS AND DESCRIPTION

1. Single acting Hydraulic Cylinder

2. Oil Tank

3. Hydraulic Pump with Motor

4. Solenoid Valve with Control Unit

 5. Dash pad and

6. Connectors

7. HOSE COLLAR AND CONNECTOR

8. BEARING WITH BEARING CAP

9. WHEEL ARRANGMENT

10. TRAILER BODY

1. SINGLE ACTING HYDRAULIC CYLIMDER:

Piston:

The piston is a cylindrical member of certain length which reciprocates inside the

cylinder. The diameter of the piston is slightly less than that of the cylinder bore diameter

and it is fitted to the top of the piston rod. It is one of the important parts which convert

the pressure energy into mechanical power.

The piston is equipped with a ring suitably proportioned and it is relatively soft

rubber which is capable of providing good sealing with low friction at the operating

pressure. The purpose of piston is to provide means of conveying the pressure of air

inside the cylinder to the piston of the oil cylinder.

Generally, piston is made up of

 Aluminium alloy-light and medium work.

 Brass or bronze or CI-Heavy duty.

 The piston is single acting spring returned type. The piston moves forward when

the high-pressure air is turned from the right side of cylinder. The piston moves backward

when the solenoid valve is in OFF condition. The piston should be as strong and rigid as

possible. The efficiency and economy of the machine primarily depends on the working

of the piston. It must operate in the cylinder with a minimum of friction and should be

able to withstand the high compressor force developed in the cylinder and also the shock

load during operation.

The piston should posses the following qualities.

a. The movement of the piston not creates much noise.

b. It should be frictionless.

c. It should withstand high pressure.

Piston Rod

The piston rod is circular in cross section. It connects piston with piston of other

cylinder. The piston rod is made of mild steel ground and polished. A high finish is

essential on the outer rod surface to minimize wear on the rod seals. The piston rod is

connected to the piston by mechanical fastening. The piston and the piston rod can be

separated if necessary.
 One end of the piston rod is connected to the bottom of the piston. The other end

of the piston rod is connected to the other piston rod by means of coupling. The piston

transmits the working force to the oil cylinder through the piston rod. The piston rod is

designed to withstand the high compressive force. It should avoid bending and withstand

shock loads caused by the cutting force. The piston moves inside the rod seal fixed in the

bottom cover plate of the cylinder. The sealing arrangements prevent the leakage of air

from the bottom of the cylinder while the rod reciprocates through it.

Cylinder Cover Plates

The cylinder should be enclosed to get the applied pressure from the compressor

and act on the pinion. The cylinder is thus closed by the cover plates on both the ends

such that there is no leakage of air. An inlet port is provided on the top cover plate and an

outlet ports on the bottom cover plate. There is also a hole drilled for the movement of

the piston.

The cylinder cover plate protects the cylinder from dust and other particle and

maintains the same pressure that is taken from the compressor. The flange has to hold the

piston in both of its extreme positions. The piston hits the top plat during the return

stroke and hits the bottom plate during end of forward stroke. So the cover plates must

be strong enough to withstand the load.

Cylinder Mounting Plates:

 It is attached to the cylinder cover plates and also to the carriage with the help of

‘L’ bends and bolts.

Cylinder Tube Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

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

2. Hard drawn Aluminium Hard drawn steel tube

Aluminium tube Castings tube.

4. Hard drawn Brass, Bronze, Iron or

Brass tube Castings, welded steel tube

End Cover Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminium stock Aluminium stock Hard tensile

(Fabricated) (Fabricated) Castings

2. Brass stock Brass stock

 (Fabricated) (Fabricated)

3. Aluminium Aluminium, Brass,

Castings iron or steel Castings.

Piston Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1.Aluminium Aluminium Castings Aluminium Forgings,

Castings Brass (Fabricated) Aluminium Castings.

2. Bronze (Fabricated) Bronze (Fabricated)
3. Iron and Steel Brass, Bronze, Iron or

Castings Steel Castings.

Mount Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminium Aluminium, Brass High Tensile

Castings And Steel Castings Steel Castings

2. Light Alloy High Tensile

(Fabricated) Steel Fabrication

Piston Rod Materials:

MATERIAL FINISH REMARKS

MILD STEEL Ground and polished hardened, Generally preferred chrome

ground and polished. plated

STAINLESS STEEL Ground and Polished Less scratch resistant than

chrome plated piston rod

2. OIL TANK:

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

provide the oil tank.

Hydraulic fluids

Almost any free-flowing liquid is suitable as a hydraulic fluid, as long as it will

not chemically injure the hydraulic equipment. For example, an acid, although free-

flowing, would obviously be unsuitable because it would corrode the metallic parts of the

system.

Water, except for its universal availability, suffers from a number of serious

defects as a possible hydraulic fluid. One such defect is that it freezes at a relatively high

temperature, and, in freezing, expands with tremendous force, destroying pipes and other

equipment. Also, it rusts steel parts; and it is rather heavy, creating considerable amount

of inertia in a system of any size.

 The hydraulic fluid used in submarine hydraulic systems is a light, fast-flowing

lubricating oil, which does not freeze or even lose its fluidity to any marked degree even

at low temperatures, and which possesses the additional advantage of lubricating the

internal moving parts of the hydraulic units through which it circulates.

Since this oil, a petroleum derivative, causes rapid deterioration of natural rubber,

synthetic rubber is specified for use in these systems as packing and oil seals.

3. HYDRAULIC PUMP WITH MOTOR:

In our project, the rotary vacuum pump with motor is used.

The Rotary vacuum pump

The widely used type of pump is the rotary vacuum pump whose operating

principle is illustrated bellow. Here the mechanical action which moves the fluid is

furnished by the vacuum force.

The oil is trapped by the pump and carried by them around the inside channels of

the pump body. This sucks in oil at the inlet port (the left-hand port), and discharges it at
the outlet port (the right-hand port). The oil cannot get back through the outer channels to

the inlet side of the pump because the vacuum pump is rotating by giving 230Volt A.C

supply

Therefore a continuous flow of oil is set up in the direction. This flow continues as

long as the vacuum pump continues to rotate. Pumps using the vacuum principle are

popular because of their quiet performance and because their simplicity of design results

in relative freedom from service troubles.

4. SOLENOID VALVE (OR) CUT OFF VALVE:

The Solenoid control valve is used to control the flow direction is called cut off

valve or solenoid valve. This solenoid cut off valve is controlled by the electronic control

unit which is attached in the dash pad itself.

In our project separate solenoid valve is used for flow direction. One is used to

control the oil direction from oil tank to the hydraulic cylinder. Another one is used to

return the oil from the hydraulic cylinder to the reservoir.

5. DASH PAD:
 The Dash pad contains the Electronic control circuit, and Buttons. The button is

activated at the time of we required, the control circuit gives the control signal to the

solenoid valve, so that the solenoid valve operate.

6. CONNECTORS:

In our system there are two types of connectors used; one is the hose connector and

the other is the reducer.

Hose connectors normally comprise an adapter (connector) hose nipple and cap

nut. These types of connectors are made up of brass or Aliminium or hardened steel.

Reducers are used to provide inter connection between two pipes or hoses of

different sizes. They may be fitted straight, tee, “V” or other configurations. These

reducers are made up of gunmetal or other materials like hardened steel etc.

7. BEARING WITH BEARING CAP:

 The bearings are pressed smoothly to fit into the shafts because if hammered the

bearing may develop cracks. Bearing is made upof steel material and bearing cap is mild

steel.

INTRODUCTION

Ball and roller bearings are used widely in instruments and machines in order

to minimize friction and power loss. While the concept of the ball bearing dates

back at least to Leonardo da Vinci, their design and manufacture has become

remarkably sophisticated.

This technology was brought to its p resent state o f perfection only

after a long period of research and development. The benefits of such specialized

research can be obtained when it is possible to use a standardized bearing of the

proper size and type.

However, such bearings cannot be used indiscriminately without a careful

study of the loads and operating conditions. In addition, the bearing must be

provided with adequate mounting, lubrication and sealing. Design engineers have

usually two possible sources for obtaining information which they can use to select a

bearing for their particular application:

 a) Textbooks

b) Manufacturers’

Catalogs Textbooks are excellent sources; however, they tend to be overly

detailed and aimed at the student of the subject matter rather than the practicing

designer. They, in most cases, contain information on how to design rather than

how to select a bearing for a particular application. Manufacturers’ catalogs, in

turn, are also excellent and contain a wealth of information which relates to the

products of the particular manufacturer. These catalogs, however, fail to provide

alternatives – which may divert the designer’s interest to products not

manufactured by them. Our Company, however, provides the broadest selection of

many types of bearings made by different manufacturers.

For this reason, we are interested in providing a condensed overview of the

subject matter in an objective manner, using data obtained from different texts,

handbooks and manufacturers’ literature. This information will enable the reader

to select the proper bearing in an expeditious manner. If the designer’s interest

exceeds the scope of the presented material, a list of references is provided at the end

of the Technical Section. At the same time, we are expressing our thanks and are

providing credit to the sources which supplied the material presented here.

Construction and Types of Ball Bearings

 A ball bearing usually consists of four parts: an inner ring, an outer ring, the balls

and the cage or separator.

To increase the contact area and permit larger loads to be carried, the balls run in

curvilinear grooves in the rings. The radius of the groove is slightly larger than the radius

of the ball, and a very slight amount of radial play must be provided. The bearing is thus

permitted to adjust itself to small amounts of angular misalignment between the

assembled shaft and mounting. The separator keeps the balls evenly spaced and prevents

them from touching each other on the sides where their relative velocities are the greatest.

Ball bearings are made in a wide variety of types and sizes. Single-row radial bearings

are made in four series, extra light, light, medium, and heavy, for each bore, as illustrated

in Fig. 1-3(a), (b), and (c).

100 Series 200 Series 300 Series Axial Thrust Angular Contact Self-aligning

Bearing Fig. 1-3 Types of Ball Bearings

The heavy series of bearings is designated by 400. Most, but not all,

manufacturers use a numbering system so devised that if the last two digits are multiplied

by 5, the result will be the bore in millimeters. The digit in the third place from the right

indicates the series number. Thus, bearing 307 signifies a medium-series bearing of 35-
mm bore. For additional digits, which may be present in the catalog number of a bearing,

refer to manufacturer’s details.

Some makers list deep groove bearings and

bearings with two rows of balls. For bearing

designations of Quality Bearings & Components

(QBC), see special pages devoted to this purpose. The radial bearing is able to carry a

considerable amount of axial thrust.

However, when the load is directed entirely along the axis, the thrust type of

bearing should be used. The angular contact bear- ing will take care of both radial and

axial loads. The self-aligning ball bearing will take care of large amounts of

angular misalignment. An increase in radial capacity may be secured by using rings

with deep grooves, or by employing a double-row radial bearing. Radial bearings are

divided into two general classes, depending on the method of assembly. These are the

Conrad, or nonfilling-notch type, and the maximum, or filling-notch type. In the Conrad

bearing, the balls are placed between the rings as shown in Fig. 1-4(a). Then they are

evenly spaced and the separator is riveted in place. In the maximum-type bearing, the

balls are a (a) (b) (c) (d) (e) (f) 100 Series Extra Light 200 Series Light 300 Series

Medium Axial Thrust Bearing Angular Contact Bearing Self-aligning Bearing Fig. 1-3
Types of Ball Bearings Fig. 1-4 Methods of Assembly for Ball Bearings (a) Conrad

or non-filling notch type (b) Maximum or filling notch type

8. WHEEL ARRANGEMENT:

The wheels are fitted to the body of the vehicle with the help of end bearing

and bearing caps. The wheels are made up of fiber material.

9. TRAILER BODY: -

The trailer body is made up of mild steel sheet metal. This frame is look like a

small model trailer.

BATTERY

SPECIFIC GRAVITY:

Measuring the specific gravity of the electrolyte generally checks the state of

discharge for a lead-acid cell. Specific gravity is a ratio comparing the weight of a

substance with the weight of a substance with the weight of water. For instance,

concentrated sulfuric acid is 1.835 times as heavy as water for the same volume.

Therefore, its specific gravity equals 1.835. The specific gravity of water is 1, since it is

the reference

In a fully charged automotive cell, mixture of sulfuric acid and water results in a

specific gravity of 1.280 at room temperatures of 70 to 80ºF. As the cell discharges, more
water is formed, lowering the specific gravity. When it is down to about 1.150, the cell is

completely discharged.

Specific-gravity readings are taken with a battery hydrometer. Note that the

calibrated float with the specific gravity marks will rest higher in an electrolyte of higher

specific gravity.

The decimal point is often omitted for convenience. For example, the value of

1.220 is simply read “twelve twenty”. A hydrometer reading of 1260 to 1280 indicates

full charge, approximately 12.50 are half charge, and 1150 to 1200 indicates complete

discharge.

The importance of the specific gravity can be seen from the fact that the open-

circuit voltage of the lead-acid cell is approximately equal to

V = Specific gravity + 0.84

For the specific gravity of 1.280, the voltage is 1.280 = 0.84 = 2.12V, as an

example. These values are for a fully charged battery.

 CHAPTER-7

BLOCK DIAGRAM

DASH PAD

OIL TANK HYDRAULIC

PUMP SOLENOID VALVE
WITH
MOTOR

REVOLVING
MECHANISM

HYDRAULIC
CYLINDER
 CHAPTER-8

WORKING PRINCIPLE

PRINCIPLE:

Some of the general properties of liquids in open containers have been described.

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

enclosed hydraulic system.

Liquids are practically incompressible. The following two basic principles will help to

explain the behavior of liquids when enclosed:

 Liquids are practically incompressible in the pressure ranges being

considered. Stated simply, this means that a liquid cannot be squeezed into

a smaller space than it already occupies.

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

transmitted undiminished in all directions throughout the liquid (Pascal's

principle). For example, if pressure is applied at one end of a long pipe, the

liquid, being practically incompressible, will transmit the pressure equally

to every portion of the pipe.

WORKING OPERATION: -

The dash pad switch was activated at the time of any unloading condition.

The control signal is given to the solenoid valve, when the button is activated. The same

time, the motor is started which is coupled with rotary hydraulic pump. The oil is

suctioned from the oil tank and compressed oil goes to the solenoid valve.

The solenoid valve is activated at the time of dash pad button “ON”. The

compressed fluid (oil) goes to the hydraulic cylinder. The compressed oil pusses the

hydraulic cylinder piston and move forward. The RAM is fixed at the end of the single
acting hydraulic cylinder. The piston moves towards upward and the ram is lifting the

tray.

The solenoid valve is deactivated at the time of dash pad button “OFF”.

The hydraulic cylinder fluid (oil) goes to the solenoid valve. Then the oil returns back to

the oil tank, by the time of deactivating the solenoid valve. Thus the extra oil not required

to maintain the oil level in the oil tank.

CHAPTER-9

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed below.

1. Properties:

The material selected must posses the necessary properties for the proposed

application. The various requirements to be satisfied can be weight, surface finish,

rigidity, ability to withstand environmental attack from chemicals, service life, reliability

etc.
 The following four types of principle properties of materials decisively affect their

selection

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical

The various physical properties concerned are melting point, Thermal

Conductivity, Specific heat, coefficient of thermal expansion, specific gravity, electrical

Conductivity, Magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile, compressive

shear, bending, torsional and buckling load, fatigue resistance, impact resistance, elastic

limit, endurance limit, and modulus of elasticity, hardness, wear resistance and sliding

properties.

The various properties concerned from the manufacturing point of view are.

Cast ability,

weld ability,
 Brazability,

forge ability,

merchantability,

surface properties,

shrinkage,

Deep drawing etc.

2. Manufacturing Case:

Sometimes the demand for lowest possible manufacturing cost or surface qualities

obtainable by the application of suitable coating substances may demand the use of

special materials.

3. Quality Required:

This generally affects the manufacturing process and ultimately the material. For

example, it would never be desirable to go for casting of a less number of components

which can be fabricated much more economically by welding or hand forging the steel.

4. Availability of Material:
 Some materials may be scarce or in short supply. It then becomes obligatory for

the designer to use some other material which though may not be a perfect substitute for

the material designed.

The delivery of materials and the delivery date of product should also be kept in

mind.

5. Space Consideration:

Sometimes high strength materials have to be selected because the forces involved

are high and the space limitations are there.

6. Cost:

As in any other problem, in selection of material the cost of material plays an

important part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-maintenance of the

designed part are involved in the selection of proper materials.

 DESIGN OF HYDRAULIC CYLINDER

Specification:-

Diameter = 40 mm
Stroke Length = 100 mm
Shaft Dia = 12 mm

LOAD CALCULATION:

Cylinder bore = 16 Cms

= π x (16/2)²

= 201.06193 cm²

Max. Pressure = 130 kg/cm²

Load = Area x pressure

= 201.06193 x 130
= 26138.051 kg

DESIGN OF CYLINDER WALL THICKNESS:

Internal diameter = 16 Cms

Max. Internal Pressure = 130 kg/cm²

Max. Hoop stress = 360 kg/cm²

Let the external radius be r Cms.

Let the radial pressure and Hoop stress at any radius “x” be given by,

Px = (b / x²) – a --------------------- (a)

And Fx = (b / x₂) + a

At x = 8 Cms

Fx = 360 kg/cm₂

360 = (b / 8²) + a ------------------ (b)

Subtracting Equation (a) from Equation (b)

360 – 130 = (b/64) + a – (b/64) + a

230 = 2a
∴a = 115

Substituting ‘a’ to Equation (a)

130 = (b/64) – 115

 ∴b = 245 x 64

b = 15680

; Px = 0We also know that x = r

0 = (b / r²) – 9

r² = b/a

r² = 15680 / 130 = 120.61538

∴r = 10.982504 Cms

Thickness of metal,
t = 10.982504 – 8 = 2.982504
t = 3 Cms (say)

DESIGN OF BALL BEARING

Bearing No. 6202

Outer Diameter of Bearing (D) = 35 mm

Thickness of Bearing (B) = 12 mm

Inner Diameter of the Bearing (d) = 15 mm

r₁ = Corner radii on shaft and housing

r₁ = 1 (From design data book)

Maximum Speed = 14,000 rpm (From design data book)

Mean Diameter (dm) = (D + d) / 2

= (35 + 15) / 2

dm = 25 mm

WAHL STRESS FACTOR

Ks = 4C – 1 + 0.65
4C – 4 C

= (4 X 2.3) -1 + 0.65
(4 X 2.3 )-4 2.3
 Ks = 1.85

DESIGN OF BALL BEARING

Bearing No. 6204

Outer Diameter of Bearing (D) = 47 mm

Thickness of Bearing (B) = 14 mm

Inner Diameter of the Bearing (d) = 20 mm

r₁ = Corner radii on shaft and housing

r₁ = 1 (From design data book)

Maximum Speed = 14,000 rpm (From design data book)

Mean Diameter (dm) = (D + d) / 2

= (47 + 20) / 2
 dm = 33.5 mm

Spring index (C) = ( D /d )

= 12 / 2

C = 6

WALL STRESS FACTOR

Ks = 4C – 1 + 0.65
4C – 4 C

= (4 X 6) -1 + 0.65
(4 X 6 )-4 6

Ks = 1.258

DESIGN OF D.C. MOTOR

Torque in a motor:
 By the term torque, it is meant the turning or twisting moment of a force about an
axis. It is measured by the product of the force and the radius at which this force acts.

For an armature of a motor, to rotate about its centre, a tangential force is

necessary. This force is developed with in the motor itself.

Torque (T) = ½ ( Ia / A ) BDC Z Newton meters

Using the relation,

B = φ/a

= φ/(ΠD/P)ł

= φ x P / ( Π Dł )

T = ½ x (Ia / A) x Z x φ x {P/ (ΠDł) } x Dł

= φ Z P Ia / ( 2ΠA ) Newton meters

= 0.159 x φ x Z x Ia X (P/A) Newton meters

= 0.162 x φ x Z x Ia x (P/A) Kg-m

The torque given by the above equation is the developed torque in the machine.
But the output torque is less than the developed torque due to friction and windage losses.
 CHAPTER-10

ADVANTAGES, DISADVANTAGES AND APPLICATIONS

ADVANTAGES

 It requires simple maintenance cares

 Checking and cleaning are easy, because of the main parts are screwed.
 Handling is easy.
 Manual power not required
 Repairing is easy.
 Replacement of parts is easy.

DISADVANTAGES

1. Initial cost is high.

2. Separate air tank or compressor is required.
APPLICATIONS

 All hydraulic trailers

CHAPTER-11

LIST OF MATERIALS

Sl. No. PARTS Qty. Material

i. Hydraulic Double Acting Cylinder 2 M.S
ii. 3/2 solenoid Direction Control Valve 2 Aluminium
iii. Microcontroller Unit 1 Electronics
iv. Wheel 4 Rubber
v. Bearing with Bearing Cap 4 Fiber
vi. Polyethylene Tube - Polyurethene
vii. Hose Collar and Reducer - Brass
viii Stand (Frame) 1 Mild steel
Ix Dash Pad 1 Plastic
X D.C Motor 1 Aluminum
Xi Battery 1 Lead-Acid
 CHAPTER-13

CONCLUSION

This project work has provided us an excellent opportunity and experience, to use

our limited knowledge. We gained a lot of practical knowledge regarding, planning,

purchasing, assembling and machining while doing this project work. We feel that the

project work is a good solution to bridge the gates between institution and industries.
 REFERENCES

[1] Dubey and V. Dwivedi, ―Vehicle chassis analysis: load cases and boundary conditions for

stress analysis in 11th National Conference on Machines and Mechanisms. IIT, Delhi, India,

December 2003.

[2] S. Tiwari, ―Evolution of empirical relationship between high level design parameters with

performance criteria of a Ladder type chassis frame

[3] Master's thesis, Institute of Technology, Nirma University, May 2007.

[4] A.M. Harte, J.F. McNamara, ―A multilevel approach to the optimization of a composite light

rail Vehicle body shell.ǁ, Composite Structures, Elsevier, pages 447–453, 2004.

[5] Zbigniew Sekulski, ―Least-weight topology and size optimization of high-speed vehicle-

passenger catamaran Structure by genetic algorithm, Marine Structures, Elsevier, pages 691–711,

2009.

[6] V. Bhasker, R. Babu and V. Shekhar, ―Process integration and automation solutions for rapid

designing of Automotive frame structures using Altair hyper works’ In Hyper works Technology

Conference.

[7] Automotive Industry Standard. ―AIS-053: Automotive Vehicles-Types - Terminology

[8] Automotive Industry Standard. ―AIS-93: Code of practice for construction and approval of

truck cabs, truck bodies