Screw Jack
Screw Jack
Screw Jack
Jacks are used frequently in raising cars so that a tire can be changed.
A screw jack is commonly used with cars but is also used in many other
ways, including industrial machinery and even airplanes. They can be
short, tall, fat, or thin depending on the
amount of pressure they will be under and the
space that they need to fit into. The jack is
made out of various types of metal, but the
screw itself is generally made out of lead.
The Screw
The screw has a thread designed to withstand an enormous amount
of pressure. This is due to the fact that it is generally holding up heavy
objects for an extended amount of time. Once up, they normally self
lock so that they won't fall if the operator lets go, and they hold up
well to the wear of repeated use. If they are made with a ball nut, they
will last longer because there is less friction created with this type of
jack. However, they will not self lock. This can be dangerous and
handled carefully.
Operation
The jack can be raised and lowered with a metal bar that is inserted
into the jack. The operator turns the bar with his hands in a clockwise
direction. This turns the screw inside the jack and makes it go up. The
screw lifts the small metal cylinder and platform that are above it. As
the jack goes up, whatever is placed above it will raise as well, once
the jack makes contact. The bar is turned until the jack is raised to the
level needed. To lower the jack the bar is turned in the opposite
direction.
Although a jack is a simple and widely used device, the use of any
lifting device is subject to certain hazards. In screw-jack applications,
the hazards are dropping, tipping or slipping of machines or their parts
during the operation. These hazards may result in serious accidents.
The main reasons of such accidents are as follows:
(i) The load is improperly secured on the jack
(ii) The screw-jack is over loaded.
(iii) The centre of gravity of the load is off centre with respect to the
axis of the jack
(iv) The screw-jack is not placed on hard and level surface.
(v) The screw-jack is used for a purpose, for which it is not designed.
Proper size, strength and stability are the essential requirements for
the design of the screw-jack from safety considerations.
Features
All jacks have safety features to protect the user from accidental
injury. Wide bases help to stabilize a jack and prevent tilting or sinking
into soft soil. Most car jacks also come equipped with their own handle
or cranking mechanism, but alternately many of these also will accept
the flat end of a tire tool to jack up a vehicle. When in the extended
position, jacks will have a stop point that prevents the user from
overextending the jack beyond its rated capabilities. When in the
contracted position, jacks that are provided by the manufacturer will
have a storage area specially formed or designed for the jack to rest in
when not in use.
Benefits
Equipping motorists with car jacks has provided many benefits to
those who are on the road. Most importantly, jacks have equipped
drivers with the ability to change a tire in an emergency without
having to call for assistance, which can save service fees and potential
towing fees as well. Car jacks also provide the home auto enthusiast
with a tool to use in maintenance of their own vehicle with the simpler
tasks such as changing brake pads, oil and belts. When used
appropriately with safety in mind, car jacks are an essential resource
for anyone owning or operating a motorized vehicle.
SOLAR POWERED SCREW JACK
Solar Panel
Photovoltaic (PV) cells are made of special materials called
semiconductors such as silicon, which is currently the most commonly
used. Basically, when light strikes the cell, a certain portion of it is
absorbed within the semiconductor material. This means that the
energy of the absorbed light is transferred to the semiconductor. The
energy knocks electrons loose, allowing them to flow freely. PV cells
also all have one or more electric fields that act to force electrons
freed by light absorption to flow in a certain direction. This flow of
electrons is a current, and by placing metal contacts on the top and
bottom of the PV cell, we can draw that current off to use externally.
If photovoltaic cells are connected together, you have a solar
panel. You have likely seen solar panels on rooftops of homes or
businesses, but they can also exist as large arrays on open fields and
can even be found powering satellites out in space. Photovoltaic cells
use thin layers of a semi-conducting material called silicon. Silicon is
an element, and you can find it on the periodic table along with all of
the other elements. It is also what makes up sand.
Battery
The larger the battery, the more energy it can store. We selected
a 12 V deep cycle battery that can withstand the numerous charge and
recharge cycles. The most commonly used deep cycle batteries are
Nickel-Cadmium and lead-acid batteries. Nickel-Cadmium batteries
can be discharged more without harm but are more expensive than
the Lead-acid batteries.
DC Worm Gear Motor
These simple motors have some great characteristics, which
make them suitable for a wide range of applications. They are
generally low speed but capable of extremely high torque. Worm
drives offer a brake feature (by the nature of their design) which
means when there is no power applied to the worm drive, the load
cannot turn the motor.
The best worm gear drives have high efficiency between 60-80%.
Gearing arrangement
The gearing arrangement which we will be using in our project is
Gear and Pinion arrangement connecting the shaft of the motor with
the screw jack.
The Pinion will be driven by the motor shaft which will be
meshed with the Gear. The gear will drive the spindle of the screw
jack.
The current market scenario for Lifting Jacks is that scissor jacks
were easily available because of its wide usage. The Solar powered
jack on which we are working requires a screw jack. But the available
screw jacks were of very high lifting capacity and their cost was
comparatively higher.
10 2,100
15 4,500
25 8,000
35 15,000
Screw Jacks Available on E-commerce sites
Capacity:- 5 ton
Price:- 1,100/-
URL:-
https://www.indiamart.com/proddetail/mechanical-jack-
13965091848.html
These were three more screw jacks available from a different seller
on Indiamart.
NOMENCLATURE
p - Pitch of screw thread (mm)
d - Nominal diameter of screw (mm)
dc - Core diameter of screw (mm)
dm - Mean diameter of screw
α - Helix angle of screw (degree)
W - Load (kg)
μ - Coefficient of friction
P - Effort (N)
θ - Friction angle (degree)
T - Torque (N.m)
Fc - Direct compressive stress (N/mm2)
Ft - Torsional shear stress (N/mm2)
Fs - Principal shear stress (N/mm2)
n - Number of threads in engagement with the nut.
1. Design calculations to check the safety of LEAD SCREW
Maximum Load to be lifted = 5 Ton
= 50 x 103 N
= 50KN
For a 5-ton capacity screw jack, the nominal (major) diameter of the
screw spindle is 30mm.
The pitch of the screw jack used was measured to be 12mm.
The core diameter (dc) = 26mm
The mean diameter (dm) = 28mm
The material of the lead screw is stainless steel (304). The yield stress
for the stainless steel is 205 N/mm2.
The compressive stresses induced in lead screw due to load of 50KN
is given by
Fc = (W)/(/4 dc2)
= (50 x 103 x 4)/ ( x 262)
= 94.22 N/mm2.
Safety factor = 205/94.22
=2.17.
Hence, lead screw will bear 50KN easily.
The helix angle of screw = tanα =P/dm = 12/ (x28) =0.13.
Therefore, α = 7.71°
Assuming coefficient of friction between screw and nut,
μ = tanθ = 0.20.
θ = tan-1(0.20) = 11.31°
α < θ, hence it is a self-locking screw.
The turning moment required to rotate screw under design load is
given by
T = W (dm/2) tan (α+θ)
= (50x103) (28/2) tan (7.71°+11.31°) =241.30KN.mm
The shear stress due to torque,
Ft = 16T/ (πdc3)
= (16x241.30x103)/π(26)3
= 69.95N/mm2
Direct stress is given by
Fs = ½√ (Fc2 + 4Ft2)
= 1/2((94.22)2 + 4(69.95)2)1/2
= 168.60N/mm2
The lead screw material has 412N/mm2 shear strength.
Safety factor = 412/168.60 = 2.44.
Worm gears are best speed reduction system and output torque
enhancer's. With this basic property, the gearbox size will be compact
and noise level is minimum. In this drive, the output axis will be at
normal to the input axis. For high-speed reduction, select single start
worm. As the number of starts increases, the reduction also
decreases. The lead as well as the angle of helix increases as the
number of starts increases. However, self-locking property loses.
Worm drives the worm gear. If the helix angle is less than 6 degree
then the system will attain self-locking property.
The first part of worm gear motors is the worm gear itself. This
consists of a shaft with threading that spirals itself on the shaft. This
worm gear is set into the splines of another gear. The rotational speed
of the worm gear would in turn rotate the gear it is attached to. The
second part of the motor, as the name suggests, is the motor. The
motor is attached to the worm gear, turning it at different speeds
depending upon the amount of torque produced by the main gear.
Features:
1. The motor is Gear DC motor with micro-turbine worm, you can
change the wiring-connection to change motor rotation.
2. Turbo worm geared motor with self-lock, that is, in the case of
motor without electric, the output axis is fixed, self-lock.
3. These simple motors have some great characteristics, which
make them suitable for a wide range of applications.
4. They are generally low speed but capable of extremely high
torque. Worm drives offer a brake feature (by the nature of their
design) which means when there is no power applied to the
worm drive, the load cannot turn the motor. They offer a right
angle (or even left angle) gearbox for practical mounting in tight
spaces.
5. The only real downfall these have is low efficiencies. Even the
best worm gear drives only have an efficiency between 60-80%.
8
The each sulphate ion (SO4—) moves towards the cathode and
reaching there gives up two electrons becomes radical SO4, attack the
metallic lead cathode and form lead sulphate whitish in colour
according to the chemical equation.
Chemical Action during Recharging
For recharging, the anode and cathode are connected to the positive
and the negative terminal of the DC supply mains. The molecules of
the sulphuric acid break up into ions of 2H+ and SO4—. The hydrogen
ions being positively charged moved towards the cathodes, receive
two electrons from there, and form a hydrogen atom. The hydrogen
atom reacts with lead sulphate cathode forming lead and sulphuric
acid according to the chemical equation.
SO4— ion moves to the anode, gives up its two additional electrons
becomes radical SO4, react with the lead sulphate anode and form
leads peroxide and lead sulphuric acid according to the chemical
equation.
The equation should read downward for discharge and upward for
recharge.
SOLAR CELL
Photovoltaic (PV) cells are made of special materials called
semiconductors such as silicon, which is currently the most commonly
used. When light strikes the cell, a certain portion of it is absorbed
within the semiconductor material. This means that the energy of the
absorbed light is transferred to the semiconductor. The energy knocks
electrons loose, allowing them to flow freely. PV cells also all have one
or more electric fields that act to force electrons freed by light
absorption to flow in a certain direction. This flow of electrons is a
current, and by placing metal contacts on the top and bottom of the
PV cell, we can draw that current off to use externally. For example,
the current can power a calculator. This current, together with the
cell's voltage (which is a result of its built-in electric field or fields),
defines the power (or wattage) that the solar cell can produce.
When light, in the form of photons, hits our solar cell, its energy frees
electron-hole pairs.
Each photon with enough energy will normally free exactly one
electron, and result in a free hole as well. If this happens close enough
to the electric field, or if free electron and free hole happen to wander
into its range of influence, the field will send the electron to the N side
and the hole to the P side. This causes further disruption of electrical
neutrality, and if we provide an external current path, electrons will
flow through the path to their original side (the P side) to unite with
holes that the electric field sent there, doing work for us along the
way. The electron flow provides the current, and the cell's electric field
causes a voltage. With both current and voltage, we have power,
which is the product of the two.
Energy Loss
Since the light that hits our cell has photons of a wide range of
energies, it turns out that some of them will not have enough energy
to form an electron-hole pair. They will simply pass through the cell as
if it were transparent. Still other photons have too much energy. Only
a certain amount of energy, measured in electron volts (eV) and
defined by our cell material (about 1.1 eV for crystalline silicon), is
required to knock an electron loose. We call this the band gap energy
of a material. If a photon has more energy than the required amount,
then the extra energy is lost (unless a photon has twice the required
energy, and can create more than one electron-hole pair, but this
effect is not significant). These two effects alone account for the loss
of around 70 percent of the radiation energy incident on our cell.
We have other losses as well. Our electrons have to flow from one side
of the cell to the other through an external circuit. We can cover the
bottom with a metal, allowing for good conduction, but if we
completely cover the top, then photons cannot get through the
opaque conductor and we lose all of our current. To minimize these
losses, a metallic contact grid that shortens the distance that electrons
have to travel while covering only a small part of the cell surface
covers our cell.
Finishing the Cell
There are a few more steps left before we can really use our cell.
Silicon happens to be a very shiny material, which means that it is very
reflective. Photons that are reflected cannot be used by the cell. For
that reason, an antireflective coating is applied to the top of the cell
to reduce reflection losses to less than 5 percent.
The final step is the glass cover plate that protects the cell from the
elements. PV modules are made by connecting several cells (usually
36) in series and parallel to achieve useful levels of voltage and
current, and putting them in a sturdy frame complete with a glass
cover and positive and negative terminals on the back.
Solar Panel sizing
DPDT Switch
Double Pole Double Throw Switch (DPDT) Circuit
You can see above how a double pole double throw switch can allow
a circuit to be in one of two modes. When the DPDT switch is switched
one way (flipped upward in the diagram), the lamp and buzzer are
both on, while the LED and speaker are off. When the DPDT switch is
switched the other way (flipped downward), the LED and the speaker
are both on, while the lamp and buzzer are off.
This shows the dynamic 2-mode capacity that DPDT switches allow,
allowing control of four different devices (with two operational
modes).