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LIFT
By,
Kunal Kotian (4PA07ME029)
Rao Sharana Kumar (4PA08ME402)
Srinidhi (4PA07ME057)
Abdul Rahiman (4PA08ME400)
INTRODUCTION
FORK LIFT
DESCRIPTION OF PARTS
WORKING MECHANISM
DESIGN CALCULATIONS
DRAWINGS
COST ANALYSIS
FUTURE SCOPE
CONCLUSION
REFERENCE
Pipelines
This project is about providing small scale industry which are dominant in India with
custom designed fork lifts of variable capacity where the operating cost and
maintenance is just negligible hence economical and efficient. Since the whole
operating is purely manually or mechanically through cycle pedaling.
FORK LIFT
Fork lifts are the material handling devices which are used to transport the
load from one station to another.
Forklifts are either powered by gasoline, propane, or electricity. Electric
forklifts rely 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.
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 will lift the load of about 250kg . Fork is raised by turning a crank with your hand,
and you transport the goods by pedaling with your feet.
Quite a lot of forklifts are electric anyway though, but this one will moreover save
electricity along with fuel by eliminating their use. It does not require a battery too. So
it could be fairly green to start with.
But it is not applicable for hilly or sloppy areas where a large amount of power and
effort would be required which is not possible with just pedaling.
This unique design of the fork lift can be used on flat paths in industries/companies
where repeated loads are to be transported from one station to another thereby helping
in transferring the load easily which otherwise would be difficult through just manual
interference.
SIDE VIEW OF PEDAL OPERATED FORK lift
DESCRIPTION OF PARTS
Body or main chasis:
The body is rectangular in section. It is made of mild steel. The front part is called as
channel where the frame travels. It is welded with stainless steel for easy movement of the
frame and to reduce friction.
Frame:
it is rectangular in section. It is made of mild steel. Its dimensions are 1500x900mm. The
frame reciprocates inside the channel and is welded with the fork which carries the load.
Fork:
the fork is made of mild steel and is welded to the channel .The dimensions of the fork are
600mm. The load to be lifted is placed on the fork and the frame along with the fork is
lifted using worm gear mechanism.
Gear box:
The gear box consist of two shafts and idler shaft with five gears. The material used for
the gears is EN8. The gears are covered with the plates made of mild steel.
Pedal:
The input to the shaft which enables the gear to rotate inside the gear box is achieved
through pedaling. The pedals are made of steel. It is situated such that operator feels
comfortable to operate.
Sprockets:
There are two smaller diameter sprockets with diameter 65 mm which provides input to
the gear shaft and two larger diameter sprockets with diameter 160 mm is provided at the
output and is welded to the axle. The material used for the sprockets is alloy steel.
Tie rods:
The tie rods are made of mild steel. The dimensions is 400x20mm. It is connected to bell
crank which is linked to the stub axle.
Rear axle:
The rear axle is made of mild steel. The dimensions are 30mm . it is supported with
Plummer block and is connected to the wheels.
Stub axle:
The stub axle is made of mild steel. A bell crank lever with short arm diameter of 25mm
and length 90mm, a long arm taper section of length 180mm with bush diameter of
20mm.
Brake :
The brake consist of brake drum welded to the rear axle. A rod of suitable length is fixed
to the brake shoe. The brake handle is situated near to operators seat.
WORKING MECHANISM
The fork lift which we have designed consists of three main mechanism :
Lifting mechanism using Worm gear
Steering mechanism
We have designed the system for 2500N and it can be used in small scale industries.
Lifting mechanism: The load will be lifted by using worm gear assembly chain block
system. It consist of worm, worm wheel, chain and a pulley for cranking. The rotation
of pulley enables the worm to rotate which in turn rotates the worm wheel. The chain
which is fixed to the output of gear helps in lifting the load placed in the fork of the
fork lift. The below figure shows lifting mechanism.
Steering mechanism:
It consists of bell crank lever, tie rods, steering rod consisting of eccentric pivot pin. One
end of both the tie rods are connected to the pivot pin and the other end of the tie rod is
connected to the longer arm of the bell crank lever on each side. The short arm holds the
front wheels. The pivot pin is connected to the steering rod. The wheels are steered by
rotating steering wheel.
Pedaling mechanism:
This mechanism comprises of gear box. The gear box contains two shafts (one for input
and other for output).It consist of 5 gears including an idler gear. Due to pedaling the input
shaft rotates, hence gear fixed to the shaft rotates which mates with the gear on the output
shaft. An idler gear is placed to move the vehicle in forward direction. When the lever
direction is changed the 3 gear assembly with idler gear is disengaged and the other two
gears are engaged which enables the vehicle to move in reverse direction.
DESIGN CALCULATIONS
WORM GEAR
GEAR CALCULATIONS
GEAR 1 12 TEETH 24 DIA 2 no,s
GEAR 2 18 TEETH 36 DIA 1 no,s
GEAR 3 36 TEETH 72 DIA 1 no,s
GEAR 4 54 TEETH 108 DIA 1 no,s
Metric spur gears module 2 as per AISI 1146
12 to 29 tooth
AISI 1045 30 to 80 tooth
DRAWINGS
MAIN FRAME:
SLIDER FRAME:
TIE ROD :
STUB AXLE:
STUB AXLE FRAME:
GEAR BOX
SPECIFICATION
Length of horizontal chassis frame = 1500mm
Length of vertical frame = 1800mm
Width of vehicle frame = 900mm
Travel length of frame = 1450mm
Chain block capacity = 5000N
Gear box two speed (front and reverse) 3:1 velocity ratio
Single operator
COST ANALYSIS
FUTURE SCOPE
Hydraulics can be applied for lifting mechanism.
The load capacity of the system can be increased by increasing the worm
dimensions.
Other steering mechanism such as rack and pinion etc can be introduced.
CONCLUSION
The Pedal operated Fork lift which we have designed is limited to load capacity of 2500
N further improvements can be made in designing the chain blocks of higher dimension to
increase the lifting capacity .
The specialty of the existing design is that no need of providing the counter weight for
balancing since the load being lifted is transferred to the rare part of the structure through
the chain block being mounted on the ISMC which rests on the pipe frame.
Also further improvement in the movement of the vehicle can be obtained by replacing
the chain drive with differential system.
REFERENCE