Design and Development of Forkliftfinal PROJECT REPORT

CHAPTER 1
INTRODUCTION
Advancements in manufacturing technology allow companies to rapidly produce

products. This has provoked a trend to reduce bulk inventory in favor of short term
supplies. Although this allows corporations more financial freedom, it requires
warehouses to accommodate temporary, selective storage. Improved product handling
and speed can be achieved with the implementation of an Automated Guided Vehicle,
AGV.
In a traditional warehouse, human safety governs the productivity. With the help of
intelligent computers, the AGV can safely achieve higher speeds. Precision turning
allows it to accurately navigate in tight spaces.
The AGV is highly flexible as a result of remote communication. Its ability to

communicate with other autonomous vehicles provides a seamless operation. Continuous
coordination between vehicles delivers money saving efficiency.
The introduction of unmanned vehicles onto a warehouse floor has favorable effects on
safety. With the aid of environmental sensors, the AGV can detect objects in its collision
path. Automation eliminates vehicle traffic jams and their potential for accidents. For
companies building new warehouses, there are many monetary benefits to investing in
intelligent machinery. The workforce required to run the warehouse and the additional
overhead (e.g., insurance) required to support that overhead will be drastically reduced.
Increased product turn-around and faster shipping will result in more satisfied customers.
Also, automation reduces the risks of personal injury.
In general the forklift can be defined as a tool capable of lifting hundreds of kilograms. A
forklift is a vehicle similar to a small truck that has two metal forks on the front used to
lift cargo. The forklift operator drives the forklift forward until the forks push under the
JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)
Page 1
cargo, and can then lift the cargo several feet in the air by operating the forks. The forks,
also known as blades or tines, are usually made out of steel and can lift up to a few tons.
Forklifts are either powered by gasoline, propane, or electricity. Electric forklifts relay on

batteries to operate. Gasoline or propane forklifts are sometimes stronger or faster than
electric forklifts, but they are more difficult to maintain, and fuel can be costly. Electric
forklifts are great for ware house use because they do not give off noxious fumes like gas
powered machines do.
Forklifts are most often used in warehouses, but some are meant to be used outdoors. The
vast majority of rough terrain forklifts operate on gasoline, but some use diesel or natural
gas. Rough terrain forklifts have the highest lifting capacity of all forklifts and heavy
duty tires (like those found on trucks), making it possible to drive them on uneven
surfaces outdoors.
It is important for forklift operators to follow all safety precautions when using a forklift.
Drivers should be careful not to exceed the forklift’s weight capacity. Forklift operators
also need to be able to handle forklift’s rear wheel steering. Driving a forklift is similar to
driving a car in reverse, meaning that the driver must constantly steer to keep it moving
in a straight line. The driver must be aware of the forklift’s ever-changing center of
gravity and avoid making any quick sharp turns or going too fast. It is advisable that
anyone who operates a forklift be fully trained and licensed.
Forklift shave revolutionized warehouse work. They made it possible for one person to
move thousands of pounds at once. Well-maintained and safely operated forklifts make
lifting and transporting cargo infinitely easier. This is the general description of a normal
forklift truck. To enhances the technology further, this prototype module is constructed
with remote technology, there by the operatorcan walk along with the forklift for better
visibility & the container can be placed accurately (precision position). This increases the
safety of the operator.
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Why Forklift?
 The forklifts are generally used for moving heavy goods and supplies from one
place to another quickly and with less effort.
 The forklifts are small but compact machines, designed to work in tight and
narrow areas.
 The best thing is that you can choose a forklift with the right configuration and
capacity depending on your needs.
 One advantage of the forklifts is that they are capable to reach things located on
high locations.
 Without these machines, the warehouses would not be able to operate efficiently
and with easiness.
 They perform Eco-friendly operation and have longer life.
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1.1 Problem Statement
There are many reasons which yield to the creation of Automated Guided Vehicle (AGV)
around the world. Mostly the reason is to overcome the logistic problems that often
occurred in the workplaces & to make improvement to the facilities provided in the
workplaces.
Factories, industries and storage go downs need forklifts and cranes for storage and
moving large goods. Also there are a number of goods weighing around 100 – 200 kgs
that are comparatively lighter but cannot be moved around easily by human labor.
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1.2. Solution
To fill this need we here propose a 2 wheel drive forklift to lift and transport such
medium weight goods across factories & industrial warehouses. The 2 wheel drive is a
fast, efficient and low power consumption vehicle that does not require much space to
move around. It is accurate, fast, efficient and sustainable
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1.3. Objectives
 Using two wheel drive forklift to simplify driving experience.

 To make effective loading/ unloading of object.
 To reduce cost of operation by substituting fossil fuel engine.
 Avoid collision with other objects.
 Adjustment of vehicle speed.
 Ability to detect the path.
 Flexibility of path.
 Increase safety at work.
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1.4 Scope Of Current Work
The AGV operated in a model warehouse, built to scale. Its primary task was to relocate
pallets within the warehouse. An external input generated by an infrared remote control
notified the AGV whether a pallet was entering or exiting the warehouse. To get to its
destination, the vehicle traversed the warehouse by following high contrast lines. When
the four pair line follower module detected an intersection, the AGV determined whether
to turn or go straight by using an algorithm that incorporated the vehicles current location
and direction. In the first situation, the remote control signaled that a pallet was entering
the warehouse. The AGV picked up the pallet off of the incoming shipping dock and
dropped it off at one of several docks at the other end of the warehouse. Through RF
communication, the AGV told another autonomous vehicle, the ASRS, the new of the
pallet. The second situation allowed for a pallet to be shipped out of the warehouse. The
AGV waited for the ASRS to confirm that it dropped off a pallet at one of the transition
docks before it picked it up and moved the pallet to the outgoing shipping dock. While
traveling, the AGV polled two forward facing infrared range finding sensors to determine
if an object was in its forward collision path. If and object was detected, the vehicle
would stop and wait for the obstruction to be cleared. While reversing, bump sensors
detected the occurrence of a rear collision, which would permanently disable the vehicle.
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1.5. Methodology
 Visit to the industry

 Identification of problem
 Idea of project
 Collection of data
 Literature survey
 Design of CAD model
 Material selection
 Fabrication work
 Testing’s
 Conclusion
 Submission of project
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CHAPTER 2
LITERATURE SURVEY
KuldipKakade, VideetKamble, PriyankaChavan, PoojaChauhan, Dinesh Pargunde,

“Design and Fabrication of Universal Driving Wheel with the application of
Forklift: A Review”, This paper gives the review of different article paper which
includes the design of different universal wheels, their specifications, kinematic analysis
etc. Universal driving wheel is a centered wheel with angled rollers around the periphery
of the wheel which enables the load carrier to shift sideways as well as diagonally
without changing the direction of the wheel. Conventional wheels’ drawbacks are
overcome by designing of the universal driving wheel which can perform the task with
the more efficiency and less space constraints. Universal driving wheel allows vehicle to
move at any degree translation when moving at a certain speed and rotation direction. It
is a low cost proto type model which allows high mobility in complex environment.
Sneha Vishnu More, “The study of Efficiency and Effectiveness of Warehouse

Management in the context of Supply Chain Management”, In supply chain
management, modern warehousing firms and distribution centers are overwhelmed with
information related to the flows and storage of goods and services. The efficient and
effective utilization of logistics-related information can enhance firms' ability to reduce
costs while simultaneously improving customer satisfaction. Warehouse management
systems (WMS) are frequently implemented and used with these goals in mind. The
current research examines resource-based empirical justification for the pursuit and
implementation of WMS. The effective and efficient management of any organization
requires that all its constituent elements operate effectively and efficiently as individual
SBUs / facilities and together as an integrated whole corporate. In today’s competitive
market environment companies are continuously forced to improve their warehousing
operations. Many companies have also customized their value proposition to increase
their customer service levels, which has led to changes in the role of warehouses. This
paper highlights the findings of the study to evaluate performance levels and enhance
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productivity of the warehouses by developing a WMS various distribution and to analyse
the impact of effective and efficiency warehousing on competitive strength, enhanced
preservation & control and overall cost reduction and also to find out various factors
affecting efficiency and effectiveness of warehouse system.
AdityaVaidya, KrunalRotliwala, Mahesh Prajapati, Nikunj Patel, Rahul

Rajpurohit, “Design Of Pedal Operated Wheel Drive Forklift”, Mechanical fork lift
is an improved and advance technology that helps brought about revolution in the
mechanical industries today all heavy engineering company uses it. Widespread use of
the forklift truck had revolutionized warehousing practices before the middle of the 20th
century. A mixture of material handling systems is in the use, exact from that entirely
physical to the ones that are semi-automatic but manually controlled. Forklifts have
revolutionized warehouse work. They made it possible for one person to move thousands
of pounds at once. Well-maintained and safely operated forklifts make lifting and
transporting cargo infinitely easier. This is the general description of a normal forklift
truck. In Institutes or Colleges small goods cannot moved around easily by any human
body, so to fill this need we have propose a Pedal Operated forklift (electrical operated)
to lift and transport such medium weight goods. It is a fast, efficient and low power
consumption vehicle that does not require much space to move around.
3 Wheel Drive Forklift For Industrial Warehouse, “RajatRajendra Wade, Digvijay

K. Take, Mahesh S. Deshmukh, Pranaw A. Raut”, In today's life, there's a good type
of forklifts, from the big significant loading truck to the one that works among slim
aisles. Forklifts have become one in all the fundamental transportation tools we tend to
use in our lives. With all the forklifts in existence, we discover that their square measure
some enhancements that can be created to bring the self-propelled vehicle to a much
better performance. Mechanical fork raise is associate improved and advance technology
that helps caused revolution at intervals the mechanical industries these days all
important engineering company uses it. Widespread use of the wheeled vehicle truck had
revolutionized deposition practiced before the centre of the 20th century. a mix of cloth
handling system is at intervals the employment, actual from that entirely physical to
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people who unit of measurement semi-automatic but manually controlled. self-propelled
vehicle has revolutionized warehouse work. They created to achievable for one person to
maneuver thousands of pounds promptly. Well maintained and safely operated forklifts
build lifting and transporting freight infinitely easier. this may be the ultimate description
of a conventional wheeled vehicle truck. To enhances the technology any, this image
module is created with remote technology, there by the operator can walk at the facet of
the wheeled vehicle for higher visibility & the instrumentality area unit usually placed
accurately (precision position). this may increase the protection of the operator.
RajendraTrailokya, SanketShinde, Rahul Jadhav, SagarPujari, Prashant.D.Ingle,

“Zero Degree Steering Forklift For Warehouse”, In traditional steering mechanism
involves traditional steering principle. Its advantage is that it is very safe and even prime
the propensity and balance of vehicle at very high immediacy. But it can't be used at
highly sharp steers (i.e. steers at where vehicle has to rotate about an angle of 90 degree)
or at steers where there is not enough space for the car or automobile to rotate. This that
is arduousness connected with the traditional procedure of steering is completely replaced
by installing a four wheel steering mechanism. Four wheel steering is a comparatively
new technology, that imposes transport propensity in little cars, sedan, SUV, heavy duties
and other. In normal two wheels steering vehicles, the rear mounted of wheels are
consistently place forward therefore and do not involves an engaging the function in
regulating the steering in four wheel steering mechanism the back wheel can steer left
and right. To carry on the driving regulation as without any difficulty as possible. The
forklift cornering will conduct itself become not easily upset and controllable at greater
immediacy as well as on wet less gripped road surfaces. The vehicle reaction to steering
input becomes faster and more accurate from starting to end the vehicle enters immediacy
range. By moving the rear wheels in the prolongation further side the front wheels at slow
immediacy, the car’s steering circle is greatly made little. This action of the wheels
enables the vehicle to steer circular, without moving from the position, i.e. the forklift has
zero steering radius.
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AdityaVaidya, KrunalRotliwala, Mahesh Prajapati, Nikunj Patel, Rahul Rajpurohit
“DESIGN OF PEDAL OPERATED WHEEL DRIVE FORKLIFT” Mechanical fork
lift is an improved and advance technology that helps brought about revolution in the
mechanical industries today all heavy engineering company uses it. Widespread use of
the forklift truck had revolutionized warehousing practices before the middle of the 20th
century. A mixture of material handling systems is in the use, exact from that entirely
physical to the ones that are semi-automatic but manually controlled. Forklifts have
revolutionized warehouse work. They made it possible for one person to move thousands
of pounds at once. Well-maintained and safely operated forklifts make lifting and
transporting cargo infinitely easier. This is the general description of a normal forklift
truck.In Institutes or Colleges small goods cannot moved around easily by any human
body, so to fill this need we have propose a Pedal Operated forklift (electrical operated)
to lift and transport such medium weight goods. It is a fast, efficient and low power
consumption vehicle that does not require much space to move around.
T. Ferreira1 & I.A. Gorlach1 , “DEVELOPMENT OF AN AUTOMATED GUIDED

VEHICLE CONTROLLER USING A MODEL-BASED SYSTEMS
ENGINEERING APPROACH”, In this research, a controller for an intelligent AGV-
based material-handling system was developed using Visual Paradigm software, an
MBSE tool. The AGV controller is capable of: Autonomous retrieval and delivery of
SPS trolleys • Effective non-contact collision detection and avoidance • Continuous
operation for a duration of 16 hours before the need for battery charging • Safe operation
in the working environment In addition to the above capabilities, the AGVs proved to be
reliable when detecting control markers and responding to the input command received
from them. When both marker sensors were active at the same time, the sequence in the
PLC was incremented. This approach allowed for less magnetic tape to be used, and also
increased the probability of a successful read. The improved line-sensing capabilities,
along with the implementation of PID control, significantly improved the performance of
the AGVs. The decrease in oscillation also resulted in more reliable marker detection and
improved positioning when retrieving an SPS trolley.
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The use of a laser scanner allowed for multiple safety zones to be configured, and thus
for the AGVs to work safely in different working environments, regardless of the space
constraint.
In the experiments, two AGVs were operated together, and independently performed the
predetermined tasks in a service loop in the absence of a cell controller. However, a
dedicated cell controller would allow for more efficient operation in applications where
cycle time is critical.
The drawback of the current design is that the sequence of tasks is hard-coded into the
PLC program of the AGV, making a dedicated cell controller necessary in order for a
new sequence of tasks to be developed in a GUI and transferred to the PLC using the
Modbus protocol.
The application of System in this research demonstrated that the MBSE approach can
facilitate the sound functional design of complex controllers for industrial automation and
systems.
Ravi G. Kaithwas, Aniket A. Pattiwar, Rahul R. Ulmale, Ashish D. Wabhitkar,

“TWO WHEEL AISLE FORKLIFT”, The purpose of this paper was to focus on the
solving problems at the warehouses using forklift to carry load of lighter weight and
making it efficient n reduce the accident’s happening in warehouses due to large forklifts.
The two wheel aisle forklift is designed keeping the centre of idea to increase work
efficiency, reducing power Consumption, smaller dimension and hence aisle for
movement in narrow space of warehouses, high safety factor, time saving application,
easy controlling from on board. At the closing of this report, it is evident that there are
important areas which call for future research and analysis. The first of this is that
completely autonomous working without any human assessment. This will enable more
productivity and high reliability. Additionally, method of lifting forklift can be changed
safety measures, power consumption can be reduced. For the next step in the design of
this particular forklift, higher fidelity analysis method should be employed to ensure that
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lifting mechanism would to interesting and provide direction towards the application of
this forklift.
Suman Kumar Das, M.K.Pasan, “DESIGN AND METHODOLOGY OF

AUTOMATED GUIDED VEHICLE-A REVIEW” There are several possible
directions for further research. We can improve the guided tape type AGV utilizing better
navigation technique. It can be adopted any environment and cheap among autonomous
robot. There is significant amount of difference between theoretical and practical work
cycle value of time which can be optimized by adopting different methodology. In
addition, one could think of a relaxation of the taken holding requirement in the traffic
control scheme so that multiple vehicles can leave different at-crossing zones
simultaneously, and hence the performance of the AGV system can be improved.
N. Ashok, J. Dinesh Kumar, S. Mohamednizarudeen, “DESIGN AND ANALYSIS

OF TWO WHEEL DRIVE FORKLIFT FOR INDUSTRIAL WAREHOUSES”, The
project carried out by us made an impressing task in the field of production and
manufacturing industries. It is very useful for having the scrap collecting vehicle, because
they need not take any risk for park the vehicle. This project will reduce the cost involved
in the concern. Project has been designed to perform the entire requirement task at the
shortest time available.
A.J.Deokar, S.K.Kamble, G.P.Fagare, A.R.Naik, A.Y.Sutar , “HUMAN POWERED

FORKLIFT” , We conclude that, this project will helpful for small scale industries as it
is easy to operate with less cost and indirectly it will save the labor cost. Savings
resulting from the use of this machine will make it pay for itself with in short period of
time and it can be a great companion in any field dealing with rusted and unused metals.
It is mechanical device, does not required electricity as well as any external source of
battery. The development of mechanical forklift assures the ergonomically comfort to the
operator or worker and to reduces time required for manual lifting and handling. This
increases efficiency of productivity and it provide safety of operator while handling of
the material. It lifts maximum load up to 100 kg at maximum height of 1250 mm.
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MUARC OHS GROUP ,“A FORKLIFT REVIEW”, There is no shortage of statistics
corroborating the degree and severity to which forklifts are involved in workplace
accidents. This problem is of a global nature and exists throughout all industries
revolving around a core of root causal factors (Janicak, 1999). To date most of the
research regarding forklift safety has taken an ergonomic, occupational hygiene and
training based approach. Subsequently little advancement has occurred in the way of risk
reduction in the form of actual applied interventions.
What is most perplexing is the reluctance of the various forklift stakeholders to adopt
similar risk control strategies as initiated in road and aviation. More universal attention
needs to be directed towards the issue of forklift stability, so as ‘SAS-like’ technology is
viewed as the norm, rather than an exception. This philosophy should also extend
address the quality of the information that operators receive when handling loads.
The issue of load stability could be effectively managed by adopting a two-stage process.
This should firstly aim to provide continuous data, as to how the movement of raised load
impacts on the forklifts safe load-handling limit. This could work in a similar manner to
how an ‘attitude indicator’ provides feedback to pilots so as to overcome sensory
misconception (Allstar Networks, 2000). The second stage of this process could use the
‘attitude indicator-like’ system to prevent movement of a particular load, when the
system senses the action would compromise the overall stability of the forklift.
Development of effective stability and load controls for forklifts should occur as well as,
not instead of ROPS/FOPS devices and operator restraint systems. The array of
circumstances where these operator protection devices are effective is immense. Not to
mention the 20% predicted reduction in fatalities when these controls are implemented
together. (NOHSC, 1998)
Poor logistics planning for forklift operation in factory and warehouse environments
spawns a mass of ensuing hazards. Collisions between powered industrial vehicles,
pedestrian workers and both stationary/mobile objects, are major mechanisms of forklift
accidents. The risk of such accidents is further magnified when aisles are obstructed and
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when the forklift is loaded. Subsequently a need exists to control and alert the forklift to
the presence of such potential hazards.
An on-board proximity control system, fully integrated with logistics based speed zoning,
would be the most conclusive method of reducing the instance of fatalities occurring as a
result of various collisions. Given that most of the necessary ITS technology is already
available and that many transport terminals are now computer modeled prior to
installation, the time for such an approach is imminent.
“DESIGN AND ANALYSIS OF NEW FLEXIBLE AND SAFE FORKLIFTS”, This

project is mainly about a new design of a forklift. we did some research on the products
that already exist in the market for use. Then we studied in more details about how
forklifts work and the primary structure and some new design ideas were proposed. After
comparing their advantage / disadvantage, we finally have our new design proposal
settled and finished the 2D design schematic. Then we did the next step: display our
design idea in a 3D model. We used a CAD system (Solidworks) to create all individual
components and assembled them to a final design. All parts are introduced in this paper
with details, including the new design scissor lift. We want to make sure our forklift
deign here meets the safety requirements for use. We use mass and center of gravity
measurements to run our stress analysis, under both resting and loading conditions. Then
we discuss the stability triangle and how our forklift design is stable under resting
condition and its center of weight stays inside the safety triangle. In working conditions,
we change the load to see how center of gravity of the whole truck changes and get the
capacity of our forklift, which is 2000kg. we studied the design to ensure that it will meet
the functional requirement like the stress analysis. First we ran the analysis on one of the
two components in the lifting fork system, the fork. Not only we want to see if it is safe
for use, we also want to see how different element type can change the result of the
meshing model and the value of stress, strain and displacement. Then we ran test on the
other components of the lifting system, the support frame. We also performed analysis on
one of the most important subassembly, scissor lift. The result are very satisfying, they
are all safe for use. This paper gives a comprehensive technical parameter introduction. It
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has all the general parameters, dimensions and weight. Trucks performance and
electronic system are all included here. Future Research includes research on forklift’s
weight change and stability during the turning and speeding up process, and developing a
shifting counterweight automatically adjust the balance of the truck.
“ALGORITHM FOR LINE FOLLOWER ROBOTS TO FOLLOW CRITICAL

PATHS WITH MINIMUM NUMBER OF SENSORS” Nakib Hayat Chowdhurya,
DeloaraKhushib , Md. MamunurRashidc,This paper introduces an approach which help a
line follower robot to achieve the ability to autonomously follow a path that has straight
lines, curve, 90 degree bends, T-junctions and + junctions using minimum sensors.
Generally a line follower robot uses matrix of sensors to achieve this ability. This paper
discuss about the algorithm through which a line follower can do the same thing using an
array of sensor with minimum number of sensors. Because, if we able to decrease sensor
number, we can decrease the complexity of the robot.
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CHAPTER 3
PROPOSED WORK
3.1. Actuation or Working
The forklift required the capability to move around a model warehouse built out of a
sheet of plywood and to pick up pallets once it reached it’s destination. Two types of
actuation where needed to meet these objectives. Drive motors and tires added the
function of movement, while a third motor supported a pallet jack.
3.1.1. Wheels and Movement
The AGV was propelled by two 200 R.P.M. D.C. gear head motors, which were attached
to the rear tires. The tires were 2.2 inches in diameter and one inch wide. With the
addition of the third caster, the majority of the vehicle’s weight rested on the rear caster,
and the tires were slipping. Thick coats of rubber cement were painted onto the tires and
the vehicle regained traction. The AGV had an excellent turning radius as a result of the
platform layout. The tires resided one inch from the middle of the robot, which almost
allowed it to turn in place.
3.1.2. Forklift Mechanism
The forklift was created out of metal and mounted to the platform with screw. The screw
is made with cast iron and designed as per the pallet load requirement. The screw is
special type of lead screw which has holding capacity (for holding loads). A servomotor
or DC motor is used for movement of lead screw. Forks are mounted on lead screw with
screw nut arrangement. A controlled signal is given to the dc motor for lifting pallets to
the required height (height of shelf).
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3.2. Components of the System
3.2.1. Lead Screw
Lead screws are quiet, smooth, resistant to corrosion, self-lubricating, and often less
expensive. They are favored in situations that require higher levels of customization.
Because lead screws are virtually silent and vibration-free, they’re often used for medical
equipment like insulin pumps and in personal computing devices like desktop PCs.
Now, we use lead screw in our project i.e. up-down mechanism.
Lead screws are self-locking; there is typically no need to apply additional brakes, even
in situations where you’re lifting a vertical load during an electricity outage. However,
the higher the friction is on the sliding surface, the more power is required to drive the
load up or forward.
Material: Mild Steel
Figure 3.1: Lead screw
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3.2.2. DC Motor
A DC motor is any of a class of rotary electrical machines that converts direct current
electrical energy into mechanical energy. The most common types rely on the forces
produced by magnetic fields. Nearly all types of DC motors have some internal
mechanism, either electromechanical or electronic; to periodically change the direction of
current flow in part of the motor. DC motors were the first form of motor widely used, as
they could be powered from existing direct-current lighting power distribution systems. A
DC motor's speed can be controlled over a wide range, using either a variable supply
voltage or by changing the strength of current in its field windings. Small DC motors are
used in tools, toys, and appliances. Larger DC motors are currently used in propulsion of
electric vehicles, elevator and hoists, and in drives for steel rolling mills. The advent of
power electronics has made replacement of DC motors with AC motors possible in many
applications.
Figure 3.2 Motor
Specifications of DC motor
 Type= dc motor
 Speed=30rpm
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 Warranty= 1 Years
 Operating Voltage(V): 12
 Rated Torque(kg-cm): 1.2
 Stall Torque(kg-cm): 3.5
Stepper motor
Figure 3.3 Stepper Motor
Specifications of Stepper Motor
 Step Angle: 1.8°
 Number of Phase: 2
 Rated Voltage: 2.5-3.0V
 Rated Current: 1.6A
 Resistance per phase: 1.6E
 Inductance per phase: 3mH
 Holding Torque: 4.2 kgcm
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 Weight:300 grams
 Coil A: Red & Blue
 Coil B: Green & Black
 Length without shaft: 40mm
 Shaft Length: 23mm
 Shaft Diameter : 5mm
 Shaft Length : D-shaft
3.2.3 Lifting forks
Lifting fork is main part of fork lift .The lifting fork that directly lift the load from its
position and move the load from one position to another position safely.
Figure 3.4 Lifting Fork
3.2.4 Wheels
The wheels rolls and moves the forklift from one place to another place. We use four
wheels two at front side attached at bottom at support legs and two are at rear side. We
will provide drive to front two wheel and rear two wheels are supporting wheels .
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3.2.5 Battery
In an internal combustion engine -powered vehicle, the battery is used mainly to start the
engine. It is quite small but still pretty heavy, say 15kg- using lead-acid chemistry and
will have a capacity of 40–100Amp-hours (Ah). Lead-acid is a very well established
technology, it’s inexpensive and reliable.
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3.3. Sensors
3.3.1. proximity sensors
It was desirable for the AGV to be capable of safely traversing a warehouse without
colliding with obstacles in its path. Two forward facing Sharp GPD2D12 infrared range
finders were placed approximately two inches apart. Both where pointed 30 degrees
toward the center of the robot. Obstacles were detected when something passed into the
sensor’s line of sight. The sensors were preassembled and powered up with 3.3 volts.
The analog output was connected to the microprocessor. Because the robot was operating
in a model warehouse, close range sensors where chosen to stay consistent with scale.
The farthest distance the GPD2D12 can measure is 80 centimeters. With a body length
of 13 centimeters, the AGV is considered to be a 1:14 scale. Applying the scale, a life
size AGV could detect obstacles 35 feet in front of it.
3.3.2. line follower
Navigation will be achieved by following black lines on the warehouse floor. A four pair
line-tracking module is constructed with Optek OPB745 Reflective Object Sensors. They
are constructed with infrared light emitting diodes coupled with phototransistors, because
the reflective properties of black and white surfaces are different, the sensor will return
varying analog values relative to the surface they are above. The 12 microprocessor polls
these analog values and converts them to digital data: black is 23016 and white is 13516.
Two sensors are offset one half of a centimeter from the center of the module. This
allows the robot to center itself on a two centimeter wide strip of electrical tape. Both of
the other sensors are three centimeters from the middle. They serve to detect intersecting
black lines. Combining two center sensors with an outside sensor allows the AGV to
distinguish intersections from curves.
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Figure 3.5 Line Follower Schematic
Figure 3.6 Line follower Module
3.3.3. collision
Two active low bump sensors are located on the back of the robot. They are wired in
parallel, and the output is tied to a low priority interrupt. The interrupt is configured to a
falling edge. In the event that the interrupt is fired, the AGV permanently stops.
Page 25
3.3.4. RF link
The AGV is designed to work hand to hand with another vehicle on the warehouse floor.
Communication is achieved with a Laipac TRF-2.4G RF transceiver. The development
of this system was completed by Albert Chung, and it will be inserted into the AGV as a
“plug and play” device. Laipac merged several devices into one convenient package: a
bidirectional transmitter, Cyclic Redundancy Check generator, and an antenna. The
transceiver uses an external clock to serially input data from a microprocessor. Once the
internal data buffer is full, the chip uses Shock Burst technology to assemble a packet:
including an internally calculated preamble and CRC. Data is transmitted with a signaling
rate as high as 1Mbps. To address the possibilities of errors, the Stop and Wait Automatic
Request protocol was used.
This had several advantages over direct communication including an alternating frame
number and positive acknowledgment. If frames were received out of order, the receiver
would NAK the sender and wait for the correct frame. However, things were not perfect
and the two robots went quickly out of synchronization. To account for this, software
allowed for the dynamic resynchronization of frame numbers. The biggest source of error
was ambient noise that cross talked to our system. We implemented header error control
to help counter this. By inserting a standard header in the unused bits, the receiver could
test the incoming message. Another possibility of error comes from both devices
transmitting at the same time. Both robots were programmed with separate timeout
lengths. Thus, if one robot sent something and never received and ACK, it would resend
its packet before the other would.
Page 26
3.4 Prototype
Figure 3.7 Prototype Model
3.5 Work
3.5.1 communication
The AGV originally utilized two forms of communications in the forms of an RF

transceiver and an infrared remote control. The ASRS required more data because it
needed to keep track of the location of pallets, different shelf heights, and pallet ages.
With the remote control on the AGV, the AGV simply passed all of the information to
the ASRS and then discarded everything it did not need. This created a lot of overhead,
so the remote control was moved to the ASRS, which in turn passed the AGV the little
information it needed.
Page 27
3.5.2 queue
The AGV was much faster than the ASRS, so the delivery and storage of pallets was not
one to one. The implementation of a queue insured that the neither of the robots would
ever be sitting idly by. Upon the successful reception of an RF packet, the AGV pushed
it onto the queue. When there were no jobs being processed, the robot continually polled
the queue for a new job. The jobs where handled in a “First In First Out” order.
3.5.3 tracking
The four pair line tracking module was used to navigate the AGV on a dark brown,
glossy floor with white strips of electrical tape. Three motors speeds were defined:
medium fast, medium, and slow. Normal navigation was done with the medium fast
speed. If the vehicle started to stray off of the line, the software would notice a
difference in the values from one of the two center sensors and decrease the appropriate
motor’s speed to medium. If the vehicle completely left the line, the robot turns in the
opposite direction of the last sensor read. For example, if the robot last saw “white” on
the right-center sensor, it would turn left. The software detected an intersection when the
output from either of the outer line following sensors read “white.”
The detection of intersections allowed for mapping system on a Cartesian coordinate

system. The warehouse was laid out so that the vertical segments of line had Y values of
negative one, zero, and one (where negative one was closest to the shelves). The X
segments had values ranging from zero to four, which were coordinated with the dock
numbers. There was an obvious need for direction when the robot was turning; the robot
needed to turn right if it were traveling one away and left if it were traveling another. A
cardinal direction system was implemented: zero represented East, one represented
North, two represented West, and three represented South. Each time the vehicle turned,
the software would adjust the direction.
Page 28
3.5.4 lifting
For all jobs, the AGV first picked up a pallet and then dropped it off at a new location.
Two white lines were placed in front of each dock and allowed the arbitrating function to
make different actions. At the first line, the AGV would lower its fork before driving in.
It would raise its fork at the second line before turning around and heading toward its
destination. Similar procedures were followed when the AGV went to drop the pallet off.
3.5.5 obstacle Detection
Although there was no need for humans in the automated warehouse, people could be
unpredictable (unlike robots). Distance sensors determined if an object was in the
forward path of the vehicle. If they detected something, the robot would pause before
hecking to see if the obstruction was still present. For obvious reasons, the sensors were
temporarily disabled when the AGV was approaching the shelves. While backing up, the
rear bump sensors were activated so a rear collision could be detected. If this event
occurred, the vehicle would be permanently disabled.
3.5.6 forklift ftability
Since we already have the data about the mass properties of all the components, we need
to investigate if the forklift is safe under static conditions. This entails that forklift center
of gravity needs to stay within the safety triangle, as shown in Figure; otherwise the
forklift will tip over.
Page 29
CHAPTER 4
EXPERIMENTAL CALCULATIONS
4.1 Design /Calculations of Frame
 Consider load to be lifted= 100kg

 Required dimensions of frame ,
(l×b)= 1200 mm×900 mm
=1.2 × 0.9 m
 Maximum Bending Moment= force × perpendicular distance
=100×9.81×540×103
= 529.74×106 N/mm
 M / I = σ b/ y
M = Bending moment
I = Moment of Inertia about axis of bending that is; Ixx
y = Distance of the layer at which the bending stress is consider
(We take always the maximum value of y, that is, distance of extreme fiber from
N.A.)
 I=bd3/12
=1200×9003/12
I= 72900×106 mm4
 σb = M×y / I
=529.74×106×600/72900×106
= 4.36 N/mm2
 For compressive mode of ductile materials factor of safety (FOS) usually
recommended is in between 1.5 to 2 .
therefore, FOS=2
 The allowable shear stress for material is σallow = Syt / FOS
Where Syt = yield stress = 210 MPa = 210 N/mm2
Page 30
So σallow= 210/2 = 105 MPa = 105 N/mm2
Comparing above we get,
σb < σallow
i.e. 4.36< 105 N/mm 2
So, design is safe.
4.2 Design of lead screw
 Nominal Diameter(d)
Axial load (p) =100×9.81 =981 N
Assume length=1200 mm
P= fb × (dr4/12002) ×104
981 =1 × (dr4/12002) ×104
dr =19.38≈20 mm
Take standard or nominal diameter = 22 mm
………………from DOM Khurmi Gupta ,page no. 180, table no 6.1
We get, pitch(p)= 5 mm
 Core diameter (dc)
dc = d-p
= 22-5
dc =17 mm
 Mean diameter of screw (dm)
dm = d-0.5×p
=22-0.5×5
dm=19.5 mm≈20 mm
 Velocity ratio
V.R. =π ×d/l……………l=p=5 for single threaded screw
=π × 22/5
V.R.= 13.82
 Helix angle (α)
Page 31
tanα=(l/π×dm)
α=tan-1(l/π×dm)
= tan-1(5/π×20)
α=4.66
 Friction angle (Ø)
tan Ø=µ
Ø= tan-1(µ)
= tan-1(0.15)
Ø=8.5310
 Dimensions of Nut
Z=4×W/π×Sb×(d2-dc2)
= 4×981/π×15×(222-172)
Z=0.422≈1
Number of turns=1
Therefore, length of nut= z × p
=1 × 5
= 5 mm
 Efficiency of screw
ἠ = tanα / tan(α+Ø)
= tan(4.664)/tan(8.531+4.664)
ἠ=0.3476≈34.76%
Hence, efficiency should be less than 50% and friction angle should be greater
than helix angle to get self locking mechanism.
 Mechanical Advantage
M.A. =V.R. × ἠ
= 13.82 × 0.3476
M.A. = 4.80
Page 32
4.3 Programs / Algorithms
4.3.1 line follower
#include <Stepper.h>
constintstepsPerRevolution = 200; // change this to fit the number of steps per revolution
// for your motor
// initialize the stepper library on pins 8 through 11:
Stepper myStepper(stepsPerRevolution, 10, 11, 12, 13);
int IRsensor1 = 2;
int IRsensor2 = 3;
int val1;
int val2;
//robot
constint I1 = 4;
constint I2 = 5;
constint I3 = 6;
constint I4 = 7;
int state;
Page 33
//ultra
inttrigPin = 8;
intechoPin = 9;
long duration;
intdistance_cm;
intdistance_in;
void setup()
pinMode(I1, OUTPUT);
pinMode(IRsensor1, INPUT);
pinMode(trigPin, OUTPUT);
pinMode(echoPin, INPUT);
Serial.begin(9600);
myStepper.setSpeed(100);
Page 34
}
void loop()
Ultra();
if (Serial.available() > 0) // Ckeck for command Recieved
state = Serial.read();
//reverse
if (state == '1')
digitalWrite(I1, HIGH);
digitalWrite(I2, LOW);
//backward
else if (state == '2')
Page 35
//right
//left
Page 36
//stop
else if ( state == '6')
Serial.println("clockwise");
myStepper.step(stepsPerRevolution);
// delay(500);
Page 37
{
Serial.println("counterclockwise");
myStepper.step(-stepsPerRevolution);
// delay(500);
void Ultra()
digitalWrite(trigPin, LOW);
delayMicroseconds(100);
digitalWrite(trigPin, HIGH);
duration = pulseIn(echoPin, HIGH);
// Calculating the distance
distance_cm = duration / 58;
distance_in = duration / 148;
Page 38
Serial.print("Distance: ");
Serial.print(distance_cm);
Serial.println(" centimeters");
delay(1000);
if ( distance_cm>= 5)
// voidMotorstep()
// {
//
// if( state=='1')
// {
// Serial.println("clockwise");
Page 39
// myStepper.step(stepsPerRevolution);
// // delay(500);
// }
//else if ( state=='2')
//{
// Serial.println("counterclockwise");
// myStepper.step(-stepsPerRevolution);
// // delay(500);
//}
//}
4.3.2 lifting mechanism
#include <Stepper.h>
constintstepsPerRevolution = 200; // change this to fit the number of steps per revolution
// for your motor
// initialize the stepper library on pins 8 through 11:
Stepper myStepper(stepsPerRevolution, 10, 11, 12, 13);
int IRsensor1 = 2;
int IRsensor2 = 3;
Page 40
int val1;
int val2;
//robot
constint I1 = 4;
constint I2 = 5;
constint I3 = 6;
constint I4 = 7;
int state;
//ultra
inttrigPin = 8;
intechoPin = 9;
long duration;
intdistance_cm;
intdistance_in;
void setup()
Page 41
pinMode(trigPin, OUTPUT);
pinMode(echoPin, INPUT);
Serial.begin(9600);
myStepper.setSpeed(100);
void loop()
Ultra();
if (Serial.available() > 0) // Ckeck for command Recieved
state = Serial.read();
//reverse
if (state == '1')
Page 42
//backward
//right
Page 43
//left
//stop
Page 44
}
Serial.println("clockwise");
myStepper.step(stepsPerRevolution);
// delay(500);
Serial.println("counterclockwise");
myStepper.step(-stepsPerRevolution);
// delay(500);
void Ultra()
Page 45
digitalWrite(trigPin, HIGH);
duration = pulseIn(echoPin, HIGH);
// Calculating the distance
distance_cm = duration / 58;
distance_in = duration / 148;
Serial.print("Distance: ");
Serial.print(distance_cm);
Serial.println(" centimeters");
delay(1000);
if ( distance_cm>= 5)
Page 46
}
// voidMotorstep()
// {
//
// if( state=='1')
// {
// Serial.println("clockwise");
// myStepper.step(stepsPerRevolution);
// // delay(500);
// }
//else if ( state=='2')
//{
// Serial.println("counterclockwise");
// myStepper.step(-stepsPerRevolution);
// // delay(500);
//}
//}
Page 47
CHAPTER 5
EXPERIMENTAL RESULTS (ANALYSIS AND TESTING)
For the static analysis, we have already got result from calculations that maximum
loading capacity of forklift is 100kg.100kg convert to force is around 1000N. We have a
fork structure like a plate; therefore all the force acts symmetrically on its surface. As
fig.5.1.1 is the geometry and fig.5.1.2 is the model get after meshing. Then we apply a
surface load of 1000N on fork, since top of the fork is attached to the screw (lead screw)
and frame. Hence we fixed ‘A’ as a boundary condition.
5.1 Fork (lifting mechanism)
Figure5.1.1 Geometry
Page 48
Figure 5.1.2 Meshing
Figure 5.1.3 Number of Nodes & Elements
Page 49
Page 50
Figure 5.1.4 Boundary conditions
Figure5.1.
5 Directional deformation
Page 51
Figure 5.1.6 Equivalent Stress
Figure 5.1.7 Maximum shear Stress
Page 52
Fig.5.1.6 & Fig.5.1.7 are the stress analysis of the fork. As shown in fig. corner of the
fork is bend which means that a part of fork is taking biggest stress. So the corner is the
place where fracture will mostly occur.
Figure 5.1.8 Total Deformation
Fig.5.1.8 is the displacement result of the fork the maximum displacement is 0.67mm and
happens at the front of fork tip. The colour of fork is all blue which means the fork is safe
when applied 1000N force.
Page 53
5.2 Lead screw
The load considered on lead screw is uniform in all direction; therefore we have to define
the load throughout the length of lead screw. We have calculated the load on lead screw
from bending moment of fork and applied the load for analysis.
Figure 5.2.1 Geometry
Page 54
Figure 5.2.4 Boundary conditions
Figure 5.2.4 shows the support boundary conditions as the one end of lead screw is fixed
to the motor.
Page 55
Figure 5.2.5 Maximum shear stress
Figure 5.2.6 Equivalent stress
Fig.5.2.5 & Fig.5.2.6 are stress analysis and blue colour shows there would not be any
stress of failure.
Page 56
Fig.5.2.7 is the deformation analysis of lead screw the maximum displacement is

0.014422 mm, so there would not be any harmful deformation. And our lead screw is
safe.
Page 57
5.3 Frame
Figure 5.3.1 Geometry
Page 58
Figure 5.3.4
Fig.5.3.4 shows the surface load of about 495N it carries battery, electronic circuits and
other components. So we have considered it as a surface load.
Figure 5.3.5 Equivalent stress
Page 59
Figur
e 5.3.6 Maximum shear stress
From the analysis of frame in Fig. 5.3.6 we got that, there would not be any damage to
the frame.
Page 60
CHAPTER 6
COST ESTIMATION
SR.NO COMPONENT NAME PRICE (RS)

1 Frame channel 850
2 Cutting & Welding 750
3 Battery (12V) 875
4 Arduino UNO 425
5 DC Motor (2 QTY) 1200
6 Stepper Motor 1400
7 Wheels (4 QTY) 200
8 L29 3D Motor Driver 300
9 HC05 Bluetooth 150
10 L298 Motor Driver 300
11 Analog, Digital & power pins 160
12 Ultrasonic sensor 149
13 IR sensors (2 QTY) 239
14 9W EW Battery 25
15 Plywood 200
16 Screw Raw Material & Machining 1200
17 Forklift plate 425
18 Bending/Painting 170
19 Coupling 250
20 Other Expenses 1500
Total 10768/-
Page 61
CHAPTER 7
CONCLUSION
The development of Mechanical forklift assures the ergonomically comfort to the

operator or worker and to reduces time required for manual lifting and handling. It lifts
the maximum load of 100 Kg. This increases efficiency of productivity & it provide
safety of operator while handling of the material. All deliverables set forth in the project
proposal were successfully met. The designer initially intended the AGV to be a super
fast vehicle. Even though it could follow lines at high speeds, it occasionally missed
intersections. Although the AGV had to be slowed down, it was still much faster than the
ASRS, which met specifications. The forklift mechanism was not built when the platform
was designed and assembled, and the original concept for the forklift failed. The limited
amount of space hindered subsequent ideas for the forklift, and several different designs
were prototyped before the final version was built. However, the forklift turned out very
well and the wait was well worth it.
The system that is being produced is totally based on mechanical and electronics
contents. With the help of sensors and actuators the system would do the work of
controlling warehouses. As one of the objective of this project High demands on
manufacturers have left their shipping warehouses in havoc. Human error has a negative
effect on safety, efficiency, and quality. These expenses will reduced with the
introduction of an Automated Guided Vehicle, AGV. A driverless, intelligent forklift
uses an optical path to quickly and safely traverse a warehouse. Its capabilities will be
enhanced by the ability to send and receive tasks through RF data communication.
Applications in the various field such as industry, military, medical, etc. can be used in
great extent. Optimization of the mobile robot can be achieved by the utilization of
universal driving wheel.
Page 62
The AGV is a productivity increasing feature in a factory. During the manufacturing of
this AGV we had found many of intelligence that can be given to it. We provide the basic
functions like line following and collision avoidance. And the main function,
transportation of goods from station to station.
Features of Model
 To increase speed of delivery.

 Adjustment of vehicle speed
 Flexibility of path
 Avoid collision with other objects
 Reduction in labour cost.
 Ability to detect the path.
 Increase safety at work
Current work
Figure 7.1
Page 63
CHAPTER 8
REFERENCES
 KuldipKakade, VideetKamble, PriyankaChavan, PoojaChauhan, Dinesh

Pargunde, “Design and Fabrication of Universal Driving Wheel with the
application of Forklift: A Review”, International Journal of Scientific &
Engineering Research, ISSN 2229-5518Volume 9, Issue 5, May-2018.
 Sneha Vishnu More, “The study of Efficiency and Effectiveness of Warehouse
Management in the context of Supply Chain Management”, International Journal
of Engineering Technology, Management and Applied Sciences, ISSN 2349-
4476, Volume 4, Issue 8, August 2016.
 AdityaVaidya, KrunalRotliwala, Mahesh Prajapati, Nikunj Patel, Rahul
Rajpurohit, “Design Of Pedal Operated Wheel Drive Forklift”, International
Journal of Design and Manufacturing Technology (IJDMT), ISSN : 0976 – 7002,
Volume 9, Issue 1, Jan-April, pp. 17–22.
 3 Wheel Drive Forklift For Industrial Warehouse, “RajatRajendra Wade, Digvijay
K. Take, Mahesh S. Deshmukh, Pranaw A. Raut”, International Research Journal
of Engineering and Technology (IRJET), ISSN: 2395-0056 Volume: 05 Issue: 02,
Feb-2018.
 RajendraTrailokya, SanketShinde, Rahul Jadhav, SagarPujari, Prashant.D.Ingle,
“Zero Degree Steering Forklift For Warehouse”, International Journal of
Scientific & Engineering Research, ISSN 2229-5518, Volume 9, Issue 5, May-
2018.
 Table 4.1: Basic Dimensions of Square Threads in mm ,Khurmi Gupta
 FAN Jie et al, “Design of an Electric Forklift”, Computer Aided Drafting and
Manufacturing, Vol. 25, No. 3, September 2015, pp – 39-42
 Yogendra Panta et al, “Static Analysis of a Forklift”, ASEE North Central
Section Conference, American Society for Engineering Education, 2015, pp- 1-12
Page 64
 Sachin Ugale et al, “Design, Development and Modelling of Forklift”,
International Journal of Engineering Research & Technology, ISSN: 2278-0181,
Vol. 3, Issue 4, April 2014, pp- 1234-1238
 Sachin Ugale et al, “Design and Structural Analysis of Mechanical Forklift using
ANSYS Software”, International Journal of Research in Advent Technology, E-
ISSN: 2321-9637, Vol. 2, No. 5, May 2014, pp-234-237
Books-
 R. S. Bridger, “Introduction to Ergonomics”, CRC press , 3rd edition
 V. B. Bhandari, “Design of Machine Element”, Tata McGraw-Hill, 3rd edition,
2010.
 S. S. Ratan, Theory of Machine, Tata McGraw-Hill, 3rd edition, 2009.
 B. L. Theraja, “Electrical Techonology”, S. Chand Publications, 23rd edition
 Kalaikathir Achchagam, “Design Data- Data Book of Engineers”, P.S.G. College
of Technology, Coimbatore
Page 65
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CHAPTER 1

Advancements in manufacturing technology allow companies to rapidly produce

The AGV is highly flexible as a result of remote communication. Its ability to

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

Forklifts are either powered by gasoline, propane, or electricity. Electric forklifts relay on

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

 Using two wheel drive forklift to simplify driving experience.

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

 Visit to the industry

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

KuldipKakade, VideetKamble, PriyankaChavan, PoojaChauhan, Dinesh Pargunde,

Sneha Vishnu More, “The study of Efficiency and Effectiveness of Warehouse

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

AdityaVaidya, KrunalRotliwala, Mahesh Prajapati, Nikunj Patel, Rahul

3 Wheel Drive Forklift For Industrial Warehouse, “RajatRajendra Wade, Digvijay

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

RajendraTrailokya, SanketShinde, Rahul Jadhav, SagarPujari, Prashant.D.Ingle,

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

T. Ferreira1 & I.A. Gorlach1 , “DEVELOPMENT OF AN AUTOMATED GUIDED

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

Ravi G. Kaithwas, Aniket A. Pattiwar, Rahul R. Ulmale, Ashish D. Wabhitkar,

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

Suman Kumar Das, M.K.Pasan, “DESIGN AND METHODOLOGY OF

N. Ashok, J. Dinesh Kumar, S. Mohamednizarudeen, “DESIGN AND ANALYSIS

A.J.Deokar, S.K.Kamble, G.P.Fagare, A.R.Naik, A.Y.Sutar , “HUMAN POWERED

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

“DESIGN AND ANALYSIS OF NEW FLEXIBLE AND SAFE FORKLIFTS”, This

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

“ALGORITHM FOR LINE FOLLOWER ROBOTS TO FOLLOW CRITICAL

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

3.1. Actuation or Working

3.1.1. Wheels and Movement

3.1.2. Forklift Mechanism

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

3.2.1. Lead Screw

Material: Mild Steel

Figure 3.1: Lead screw

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

Figure 3.2 Motor

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

 Rated Torque(kg-cm): 1.2

 Stall Torque(kg-cm): 3.5

Figure 3.3 Stepper Motor

Specifications of Stepper Motor

 Step Angle: 1.8°

 Rated Voltage: 2.5-3.0V

 Rated Current: 1.6A

 Resistance per phase: 1.6E

 Inductance per phase: 3mH

 Holding Torque: 4.2 kgcm

JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)

 Coil A: Red & Blue

 Coil B: Green & Black

 Length without shaft: 40mm

 Shaft Length: 23mm

 Shaft Diameter : 5mm

 Shaft Length : D-shaft

3.2.3 Lifting forks