Irjet V5i9209 PDF

Download as pdf or txt
Download as pdf or txt
You are on page 1of 12

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 05 Issue: 03 | Mar-2018 www.irjet.net p-ISSN: 2395-0072

Design and Development of Mechanical Forklift


Lobo Allwyn M1, Khebude Karan N2, Adsul Ganesh B3, Bhosale Prathamesh G4,

Khade Omkar S5, Naik Abhijeet N6


1,2,3,4,5Student, Sanjeevan Engineering & Technology Institute, Panhala, MH, India
6 Professor, Dept. of Mechanical Engineering, Sanjeevan Engineering & Technology Institute, Panhala, MH, India
--------------------------------------------------------------------------***-----------------------------------------------------------------------
Abstract - Material handling process is the process of 1.2 Field of Use
movement of raw material, semi-finished goods, finished goods
through various stages of production and warehousing. It has The forklift are used to transfer material from one place to
been seen that forklift equipment is widely used in many another place. These are used in commercial areas like
industries for different applications such as lifting, safe Industrial Workshops, warehouses, Car servicing station,
delivery of material such as huge boxes, Raw materials, Institutes, Material handling and construction applications.
Cylindrical sections etc. are widely used Forklift equipment. It
consist of Lead screw & Nut arrangement. The forklift 1.3 Literature Survey
equipment is compact in size can be alternative for the manual
From the reference of actual Industrial forklift we have
lifting. Small scale industries can’t afford the huge & costly
designed our miniature and cost effective forklift. The
material handling equipment so we are designing and
structure is constructed by using C-channels, Metal frames,
manufacturing Forklift equipment for small scale industries.
lead screw, Nut etc. These materials are easily available into
Key Words: Forklift, Lead screw, Nut, Motor, Gearbox, market. From literature survey we got important
Battery, Bearing, Fork information regarding manufacturing of Forklift. It provides
information related to design consideration.
1. INTRODUCTION

The forklift can be defined as a tool of lifting hundreds of


kilogram of weight. A forklift 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 cargo, and can then lift the cargo several feet
in the air by operating the forks.[3]

The forklift works on Electric D.C. Motor. Electric forklift


are great for warehouse use because they do not give off
noxious fumes like Gas powered forklift do. Gas powered
forklift are stronger than electric forklift, but they are more
difficult to maintain and fuel are costly.

1.1 Market Survey

The market survey lets the firm to understand and realize


the real demand and potential for the product under
consideration. First and foremost, it is necessary to establish
that the proposed product will fulfill a demand in the market
or not, what is supposed to do, and the service it can offer to
the consumers.

So, we take the survey for our prototype in ‘SAFAL


INDUSTRIES’, Shiroli M.I.D.C. Kolhapur. There requirement of
miniature forklift that can list the component up to 500 Kg
economically.

After we surveyed in our institute we can found that the


educational engineering apparatus up to 200 Kg is not easy to
move from one place to another place. So the miniature
Fig- 1: Forklift
forklift is required to design that can utilized for lifting load
up to 200Kg

© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1125
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 03 | Mar-2018 www.irjet.net p-ISSN: 2395-0072

3.3 D.C. Motor-

The D.C. motor is act as prime mover which drive the screw
to raise the load. We select 12V, 2.5A, 100rpm, 100Kgcm
motor

3.4 Supporting legs-

The dimensions of supporting legs is L=640, A=75x40x5mm.


It is used to avoid to fork from tilt when it is loaded. These
legs are at either side of whole assembly.

3.5 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. At front
side Caster wheels and at rear side Rubber wheels are used.

3.6 Battery-

The battery act as power source for driving of motor. We use


battery capacity of 12V, 7.2 Ah

3.7 Lifting Forks-


Fig- 2: Motor & Gearbox Arrangement
The dimensions of lifting fork L600, A=40x40x3mm. The
2. WORKING lifting fork that directly lift the load from its position.

The Mechanical forklift works on Semi-Electric techniques. 3.8 Gearbox-


In this transfer the power from one form into another form
We cannot directly couple motor to screw as we required
using mechanical as well as electric components. The project
gearing arrangement, because motor has low torque and
works on technique of Transfer rotational motion into Linear
high speed. So, to convert motor torque and speed into
motion. For this purpose D.C. motor (12V, 2.5A) are used. The
required torque and speed. We use spur gear and pinion. The
motor are constructed with Gearbox with Gear ratio 5:1. The
motor shaft is directly couple to pinion and bull gear is
chain drive is coupled from gearbox to Lead screw using
connected to screw.
sprocket. Therefore motion is transfer to Lead screw. The
lead screw is mounted on the Guide column. The Nut are 3.9 Bearings-
fastened into the Lead screw and Roller are bolted to the Nut.
And Forks are attached to the Roller. By using roller the Bearings are used to support shaft of gearbox & Lead screw.
rotational motion of Lead screw is converted into Linear Two types of bearings are used. Deep groove ball bearing
motion. (D.G.B.B.) are used to support gearbox shaft & flange bearing
are used to support Lead screw.
3. COMPONENTS
4. DESIGN
3.1 Lead screw and Nut –
The design of mechanical forklift is derived as follows.
Lead screw and nut act as main component of our forklift. It Determine maximum load capacity, lifting height, forces
is main lifting mechanism. We use square form thread for acting on component. The material selected for forklift is
power screw because it is used to lift heavy load & it has high Mild Steel due to its properties like malleability, ductility,
efficiency than other screw forms. The material selected for strong and low cost.
screw is Mild steel and Nut is Cast iron.
4.1 Design of Lead Screw –
3.2 Guide Column-
 Mass carrying (m) = 250 Kg
The dimension of guide column is L=1370mm,
A=75x40x5mm, the guide column is used to support the  Length of screw = 1220 mm
load, wheels etc. and to enclose whole assembly of screw and
nut.  Factor of safety (FS)= 3

 Material = Mild steel {S_yt= 400N/〖mm〗^2, E=


210 ×〖10〗^3 N/〖mm〗^2}

© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1126
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 03 | Mar-2018 www.irjet.net p-ISSN: 2395-0072

1. Total load in Newton – = 5/(π(19.5))

Total Load (W) = Mass (m) × Acceleration due to gravity (g) α = 4.666º

= 250×9.81 7. Friction angle (∅) –

= 2450 N The possible value of the coefficient of friction between


screw and nut is 0.35
2. Permissible compressive stress (σ_c)-
tan∅ = μ
σ_c = S_yt/FS
= 0.35
= 400/3
∅ = 19.29º
=133.33 N/〖mm〗^2
Since ∅ > α the screw is self- locking.
3. Core diameter of screw (d_c) –
8. Torque required to lift & lower the load –
σ_c= W/[π/4×d_c^2 ]
M_t = (Wd_m)/2 ×tan(∅±α)
133.33= 2450/(π/4×d_c^2 )
For Lifting –
d_c= 4.836 mm
M_t= (2450 × 19.5)/2 × tan (19.29 + 4.666)
Table- 1: Properties of square thread
M_t= 10613.43 Nmm
Nominal Diameter d (mm) Pitch, p (mm) For lowering –
22,24,26,28 5
M_t = (2450 × 19.5)/2 × tan (19.29 - 4.666)
30,32,36 6
M_t = 6232.91Nmm
40,44 7
9. Check for shear & compressive stress failure –
48,50,52 8
1. τ = (16M_t)/(d_c^3 ) = (16(10613.43))/(π〖(17)〗^3 )
There are additional stresses due to torsional and bending
moments. The diameter should be increased to account for = 11 N/〖mm〗^2
these stresses. As a square threaded screw with 22 mm
nominal diameter and 5 mm pitch is selected. 2. σ_c= W/[π/4×d_c^2 ] = 2450/(π/4×〖17〗^2 ) = 10.79
We know, d= 22 mm, p= 5 mm N/〖mm〗^2

4. Core diameter of screw (d_c) – 10. Checking for buckling failure –


d_c= d – p 1. Moment of Inertia (I) –
= 22 – 5 I = π/64 ×d_c^4
= 17 mm
= π/64 × 〖(17)〗^4
5. Mean diameter of screw (d_m) –
= 4099.82 〖mm〗^4
d_m = d – 0.5p
2. Cross sectional area (A) –
= 22 – 0.5(5)
A = π/4 × d_c^2
= 19.5 mm

It is assumed that the screw has single start threads. = π/4 × 〖17〗^2

l = p = 5 mm = 226.98 〖mm〗^2
6. Helix angle (α) –

tan α = l/(πd_m )
© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1127
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 03 | Mar-2018 www.irjet.net p-ISSN: 2395-0072

3. Radius of gyration (K) – H = 10 mm

K = √(I/A) 3. Check for crushing failure of nut –

= √(4099.82/226.98) σ_c = W/(π/4 ⌈d^2-d_c^2 ⌉×Z)

= 4.249 mm σ_c = 2450/(π/4 ⌈〖22〗^2-〖17〗^2 ⌉×2)


4. Slenderness ratio (l/K) –
σ_c = 7.99 N/〖mm〗^2
l/K = 1220/4.249
4. Factor of safety for crushing failure –
= 287.12
FS = (0.5S_ut)/σ_c = (0.5 ×200)/7.99 = 12.51
5. Critical slenderness ratio –
So design is safe against crushing failure.
End fixity coefficient (n) = 0.25
4.3 Revolving Speed of screw –
S_yt/2 = (nπ^2 E)/(l/K)^2
 Pitch (p) = 5 mm
400/2 = (0.25π^2×210×〖10〗^3)/(l/K)^2
 Speed of raise = 1Feet/min
l/K = 50.89
Raise speed = 1 feet/min
6. Critical load on buckling (P_cr) –
= 12 inch/min
P_cr= S_ytA[1- S_yt/4nπE (l/K)^2 ]
= 12 × 25.4 mm/min
P_cr= 400 × 226.98 [1- 400/(4 ×0.25 × π^2 ×210 ×〖10〗^3 Raise speed = 304.8 mm/min
) 〖(50.89)〗^2 ]
N = 304.8/Pitch
P_cr= 45413.15 N
N = 304.8/5
7. Factor of safety for buckling Failure –
N = 60 rpm
FS = P_cr/W
4.4 Selection of Motor –
= 45413.15/2450
 Required torque of motor (M_t) = 10613.42 Nmm
= 18.53
 Required speed of motor (N) = 60 rpm
So the design is safe against buckling failure.
 Type of supply to motor = 12 Volt D.C.
4.2 Design of Nut –
Torque required to raise maximum load in Kg-cm =
(M_tRAISE )/(9.81 ×10)
 Permissible bearing pressure (S_b) = 13 N/〖mm〗^2
= 10613.42/(9.81 ×10)
 Material = Cast Iron {S_(ut )= 200 N/〖mm〗^2}
= 108.1 kg-cm
1. No. of threads in contact with screw (Z) –
Required speed of motor shaft in rpm = 60 rpm
Z = 4W/(πS_b (d^2- d_c^2))
We have to search market carefully then we find no motor
available with this specification so we choose a motor with
Z = (4 ×2450)/(π ×10 (〖22〗^2-〖17〗^2 ) )
100 rpm 100 Kg-cm torque motor.
Z = 1.23 ~ 2 Table- 2: Specification of motor
2. Axial length of Nut (H) –
Parameter Motor Specifications
H = Z× P Type of motor D.C. Car Window
Motor
H=2×5

© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1128
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 03 | Mar-2018 www.irjet.net p-ISSN: 2395-0072

Speed of motor 100 rpm 2.3 Service factor (C_s)-

Output torque of motor 100 Kgcm C_s= (Starting Torque )/(Rated Torque)
Input voltage and current 12 V 0.7A- at No load C_s= 1.5
2.5 A- at maximum
Load 2.4 Bending stress (σ_b)-

σ_b= S_ut/3
4.5 Selection of Gear –

The selection of Gears for Power Transmission σ_b= 200 N/〖mm〗^2

Gearbox for Power Transmission – 2.5 Velocity factor (C_v) –

 Changed Motor torque 〖(M_t)〗_m = 100 Kgcm = 10 × C_v=3/(3+v)

〖10〗^3 Nmm C_v = 0.375

 Changed Motor Speed (N)= 100 rpm 2.6 Find module (m)-

 Starting Torque = 150% Rated Torque m= [(60 × 〖10〗^6)/π {((KW)C_s (FS))/(z_p NC_v
(b/m)(S_ut/3)Y)}]^(1/3)
 Factor of safety (FS)= 1.5
m= 2.5 mm
 Material = Plain Carbon Steel {S_ut= 600N/〖mm〗^2}
2.7 Selection of module –
 Assume Pitch line velocity (v) = 5 m/s
For m= 2.5 mm
 (b/m) = 10
d_p^' = mz_p= 45mm
1. Gear ratio (G) –
d_g^' = mz_g= 225mm
We assuming ratio G = 5, & motor speed = 100 rpm and
Torque 100 Kg-cm but with help of gearing arrangement, we b= 10m= 25mm
getting of 500 Kg-cm torque & speed 20 rpm.
2.8 Tangential Force (P_t) –
Gear ratio (G) = T_g/T_p
P_t=(2〖(M〗_t))/(d_p^' )
= 5/1
P_t= 444.44 N
G = 5:1
2.9 Pitch Velocity (v)-
2. Estimation of Module Based on Beam strength (m) –
v= (πd_p^' N)/(60× 〖10〗^3 )
2.1 Minimum No. of teeths (z) –
v= 0.235 m/s
The minimum no. of teeths for 20° pressure angle is 18.
Therefore, 2.10 velocity factor (C_v) –
z_p = 18 C_v= 3/(3+v)
z_g = Gz = 5(18) = 90 C_v= 0.927
The Lewis form factor (Y) is 0.308 for 18 teeth. 2.11 Effective Load (P_eff)-
2.2 Power Rating (KW) – P_eff= C_s/C_v ×P_t

KW= (〖(M〗_t)2πN)/(60 × 〖10〗^6 ) P_eff= 719.15 N

KW= 0.104 2.12 Beam strength (S_b) –

S_b = mbσ_bY

© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1129
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 03 | Mar-2018 www.irjet.net p-ISSN: 2395-0072

S_b=3850N 2. Load capacity (C) –

2.13 Factor of safety (FS)- C = P〖(L_10)〗^(1/3)


FS = S_b/P_eff
C = 2450〖(36)〗^(1/3)
FS = 5.35
C = 8089.72 N
Therefore design is safe. After mounting Gearbox for Power
transmission we have to get following speed & torque: Using standard table of bearing selection,

Speed (N) = 20 rpm & Torque (M_t) = 500kg-cm C = 9950 N

4.6 Selection of Battery – C_0 = 4150 N

From battery available range in market we assume battery d = 12mm, D = 37mm, B = 12mm
capacity 12V, 7.2 Ah
But, from available bearing range in market, we are
Required battery capacity = V × I assuming suitable bearing –

= 12 × 7.2 d = 12mm, D = 28mm, B = 8mm

= 84.4 Watt Designation – DGBB 60012 Z

But Consider deep cycle of battery is 80% of total capacity of 4.8 Design of Fork –
battery
 Outer face height (D) = 50.8 mm
Running capacity of battery = 0.80 × required battery
capacity  Outer face width (B) = 50.8 mm

= 70 Watt  Inner ace height (d) = 44.8 mm

We consider following working time –  Inner face width (b) = 44.8 mm

Load raise time = 5 min  Length of fork (L) = 600 mm

Load lower time = 5 min

Travel time = 15 min

Total time of one operation cycle = 25 min

So, total time of 25 min battery requires 10 min and in 1


hour we use 3 times battery when fully charged.

4.7 Selection of bearing –

 Bearing life = 12000-20000 Hrs

 Radial load (P) = 2450 N

 Speed (n) = 50 rpm

 Assume L_10h = 12000 Hrs Fig– 3: Hollow Section of Bar

1. Bearing life (L_10) – Moment of Inertia of fork (I) -

L_10= (60 × n × L_10h)/〖10〗^6 I= 1/12 [BD^3-bd^3 ]

= 1/12 [6659702.81-4028209.56]
L_10=(60 ×50×12000)/〖10〗^6
I = 219291.10 〖mm〗^4
L_10 = 36 million rev.

© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1130
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 03 | Mar-2018 www.irjet.net p-ISSN: 2395-0072

Case I] Consider Two Fork with Point Load – 2. Find W/mm –

W/mm = W/L

= 2450/600

W/mm = 4.08 N/mm

3. Bending Moment (M_A) -

M_A = (-W×L^2)/2

Fig- 4: Deflection of fork at Point Load = (- 4.08×〖600〗^2)/2

1. Moment of Inertia for two fork (I) – M_A = -734400 Nmm

I = I_1+I_2 4. Deflection (y_max) –

= 219291.10 + 219291.10 y_max = (WL^4)/8EI

I = 438582.2 〖mm〗^4 = (4.08×〖600〗^4)/(8×210×〖10〗^3×438582.2)

2. Bending Moment (M_A) - y_max = 0.71 mm

M_A = -W × L 4.9 Buckling consideration in C-Section column –

= - 2450 × 600 Column with Eccentric Load –

M_A = - 1470000 Nmm  Outer face height (D) = 75mm

3. Deflection (y_max) -  Outer face width (B) = 40mm

y_max = (WL^3)/3EI  Thickness (t) = 5 mm

= (2450×〖600〗^3)/(3×210×〖10〗^3×438582.2 )  Material = Hot rolled steel {S_ut=440 N/mm^2, E = 210


× 〖10〗^3 N/mm^2}
y_max = 1.91 mm

Case II] Consider Two Fork with Uniform Distributed


Load –

Fig- 6: Guide column with eccentric load


Fig – 5: Deflection of fork at uniform distributed load

1. Moment of Inertia for two fork (I) –

I = I_1+I_2

= 219291.10 + 219291.10

I = 438582.2 〖mm〗^4

© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1131
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 03 | Mar-2018 www.irjet.net p-ISSN: 2395-0072

M_max = 1.47 × 〖10〗^6 Nmm

4.9 Design for ergonomics-

Fig- 7: Cross section area of C channel

1. Cross section area (A) –

A = [D×B]- [d ×b]

= [75×40] – [65 × 35]

A = 725 mm
Fig-8: Elbow rest Fig-9: Width of elbow
2. Moment of Inertia (I) – height standing

I = [(B× D^3 )/12] – [(b × d^3)/12] 1. Determine Height of Handle from Base-

= [(40 × 〖75〗^3)/12] – [(35 × 〖65〗^3)/12] Female -

 997.9mm Mean
I = 605.26 × 〖10〗^3 〖mm〗^4
 1185.0mm Maximum
3. ind -
 856.0mm Minimum
y = t d/2
Male-
= 5 + 65/2
 1072.5 mm Mean
y = 37.5 mm
 1261.0 mm Maximum
4. Section modulus (z) –
 888.0 mm Minimum
z = I/y
1.1 Taking average of male & female mean-
= (605.26 × 〖10〗^3)/37.5
(997.9+1072.5)/2=1035.2 mm
z = 16140.26 〖mm〗^3 As we know in workplaces workers always wears shoes or
any kind of footwear so the thickness of footwear is also to
5. Equivalent length (L_e) – be taken into account. So considering normal shoe sole is
approximately 25.4mm.
L_e = L/√2
1.2 Adding this extra height in average-
= 1320/√2
1035.2 + 25.4 = 1060.6mm
L_e = 933.38 mm
So the height of handle from base is 1060mm.
6. Maximum B.M. –
2. Determine Width of Handle –
M_max = P × e × sec[L_e/2 √(P/EI)]
Female-
=2450×600×sec[933.38/2√(2450/(210
×〖10〗^3×605.26 ×〖10〗^3 ))]  468.5 mm Mean

© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1132
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 03 | Mar-2018 www.irjet.net p-ISSN: 2395-0072

 609.0 mm Maximum Wheel

 373.0 mm Minimum 13. Chain Roller chain 08B, Mild Steel 1


p=12.7mm, Links=
Male- 19
14. Sprocket dp=45mm, Mild Steel 2
 546.1 mm Mean
d=22mm, N=8n
 725.2 mm Maximum 15. Gear & m=2mm, R=5:1 P.C.S. 1
Pinion
 399.0 mm Minimum
16. D.C V=12volt, - 1
2.1Taking average of male female mean Window N=100RPM, I=2.5A
Motor
(468.5+546.1)/2=507.3mm
17. Battery Lead-acid, - 1
We have to provide extra length as allowance V=12volt, 7Am-h
18. Key L=25mm, B=5mm, Mild Steel 1
So providing allowance of 45mm
H=8mm
2.2 Adding extra length of allowance- 19. Grub M6, L=5mm Mild steel 4
Screw
507.3 + 45 = 560 mm
20. Plate Square Mild Steel 1
So total length of handle bar is 560 mm
21. Switch On-off type Plastic 1
5. COMPONENT SPECIFICATIONS 22. Wire D.C. Wire, L=2m Copper 1
Table- 3: Component Specifications- 23 Handle d=30mm, Mild Steel 1
Bar L=560mm
No. Part Parameters Material QTY. 24. Rubber d=30mm, Rubber 2
Name Gripper L=125mm
1. Square dc=17mm, p=5mm, Mild Steel 1 25. Nut & Type=Hex, M8, Alloy steel 12
Lead d=22mm Bolt L=18mm
Screw
27. Flat Tray 560 350mm, Aluminium 1
2. Square L=60mm, p=5mm, Cast iron 1
t=2mm
Nut B=48mm
28. V-Tray L=560mm, =120 , Aluminium 1
3. C- L= 1370mm, Hot Rolled 2
t=2mm
Channel A=75×40×5mm Steel
Column 29 Wheel ID= 25.4 mm, Mild Steel 2
Shaft
4. C- L=640mm, Hot Rolled 2
Channel A=75×40×5mm Steel 30. Washer d= 30mm, ID= Mild Steel 2
Leg 10mm
5. Square L=600mm, Mild Steel 1 31. Quarter - Mild Steel 2
Tube A=40×40×3mm Pin
Fork
6. Roller L=150mm, Mild Steel 1 6. COST ESTIMATION
Box A=50×95×3mm
6.1 Cost of Material-
7. Roller ID= 28 mm Mild Steel 4
Table- 4: Cost of Material
9. Flange UCF 204, L=86mm, Gun Metal 2
Bearing ID= 20mm
No Components QT Cos
10. Roller DGBB 60012 Z Gun Metal 8 . Y t
Bearing
1. Lead screw And Nut 1 160
11. Rubber ID=25.4mm, 8 2” Rubber 2 0
Wheel
2. DGBB Bearing 6001 ZZ 8 240
12. Castor D= 50mm Cast Iron 2

© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1133
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 03 | Mar-2018 www.irjet.net p-ISSN: 2395-0072

3. DGBB Bearing 6203 ZZ 4 200 34. Charge Indicator 1 500


4. Flange Bearing UCF 204 2 500 35. Electric Connector switch 1 40
5. Bar for Roller = 42mm, L= 9” 1 36. 2 Pin Plug 1 10
6. Bar for Roller shaft = 16mm, L= 9” 1 37. AC Wire L= 3m 1 30
310
38. DC Wire L= 10m 1 25
7. C-Channel for Guide column & Base 1 160
75 40 5mm, L= 20 feet 0 Total Cost of Material = 12,096 /-
8. Square pipe for Roller box 1 50
6.2 Cost of Labour-
9. Sprocket , Bore= 22mm, No. of Teeth= 1 100 Table- 5: Cost of Labour
12
No. Operations QTY Cost
10. Sprocket , Bore= 17 mm, No. of 1 100
Teeth= 12 1. Roller machining 4

11. Bar for rubber wheel shaft = 25, L= 1 100 2. Roller shaft 2
15” 3. Roller Box Drilling 1
12. Pinion ID= 19mm, No. of teeth= 25, 1 75 4. Bearing Cap Machining 4
m=1.5
5. Pinion Boring 1
13. Bull Gear ID= 19 mm, No. of teeth= 1 381
127, m=1.5 6. Gearbox shaft machining 2

14. Bar for Gearbox shaft = 20mm, L= 1 50 7. Rubber wheel shaft 1


20mm machining

15. Rubber wheels 8 2”, ID= 1” 2 450 8. Quarter pin drilling 1


1870
16. Caster Wheels OD= 50mm 4 650 9. Rib cutting & Base plate 1 40
17. Base plate for Guide Support 1 320 cutting
195 195 4mm 10. Key slots (Rs 25/slot) 4 100
18. Bearing Cap for Gearbox 4 250 11. Motor shaft machining, 1 90
19. Handle Pipe L= 44” (Rs 60/8kg) 1 100 surfacing

20. Roller chain L= 15” (Rs 120/ft) 1 160 12. Sheet metal Bending 2 490

21. Fork attachment And Plate cutting 1 380 13. Welding -

22. Guide column and Handle bar support 1 150 14. Grinding -

23. Front wheel support plate 1 10 15. Cutting -


1100
24. Black paint 1 Ltr 1 16. Motor wiring & Soldering - 100
25. Thinner 1 Ltr 1
125 Total cost of Labour = 3,790/-
26. Square pipe for Fork 62” (Rs 1 280 6.3 Total cost of Project -
4.50/Inch)
27. Sheet Metal 2 490 Total cost of Project = Total Cost of Material + Total cost of
Labour
28. Cutting wheel 1 30
= 12,096 + 3,790
29. Grinding wheel 2 60
30. Welding rods (1/2 Pack) - 150 = 15,886 /-

31. Car Window Motor 12V, 2.5A, 100 rpm 1 160


0
32. Lead Acid Battery 12V, 7 Ah 1 800
33. Adapter 12V, 2A 1 180

© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1134
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 03 | Mar-2018 www.irjet.net p-ISSN: 2395-0072

screw & high power motor. Provide foldable design for


transporting in vans and trucks.

ACKNOWLEDGEMENT

We would like to thank Prof. Naik Abhijeet N. for his


guidance. His enthusiasm as well as his technical expertise,
were essential in helping us overcome many obstacles.
Without him this dissertation would not have been possible

REFERENCES

A) Research Papers-

[1] FAN Jie et al, “Design of an Electric Forklift”, Computer


Aided Drafting and Manufacturing, Vol. 25, No. 3,
September 2015, pp – 39-42

[2] Yogendra Panta et al, “Static Analysis of a Forklift”, ASEE


North Central Section Conference, American Society for
Engineering Education, 2015, pp- 1-12

[3] Sachin Ugale et al, “Design, Development and Modelling


Fig- 10: Flat Pallet Attachment of Forklift”, International Journal of Engineering
Research & Technology, ISSN: 2278-0181, Vol. 3, Issue 4,
April 2014, pp- 1234-1238

[4] 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

[5] R. S. Krishna et al, “Design and buckling strength


evaluation of a lifting beam”, International Journal of
Engineering Research and Science & Technology, ISSN:
2319-5991, Vol. 3, No. 4, November 2014, pp-184-189

[6] Vegim Imeri et al, “Dynamic Analysis of Forklift during


Load Lifting using Modeling and Simulations”,
International Journal of Current Engineering And
Technology, ISSN: 2277-4106, 2013, pp- 342-347

[7] Xiaobing Pei et al., “Design and Improvement of Material


handling apparatus in the Machine Shop of Company”,
Applied Mechanics And Material, Vol. 587-589, 2014,
pp-1950-1953
Fig- 11: V Pallet Attachment [8] Juan M. Massone, “Failure of forklift forks”, Engineering
Failure Analysis, Elsevier Ltd., January 2010, pp- 1062-
7. CONCLUSION
1068
The development of Mechanical forklift assures the
[9] H. S. Alasalami, “Static structural analysis of Caterpillar
ergonomically comfort to the operator or worker and to
D70 Forklift with different materials applied to mast and
reduces time required for manual lifting and handling. It lifts
arm assembly”, International Academy of Science,
the maximum load of 200 Kg at maximum height 1250mm.
Engineering And Technology, P-ISSN: 2319-2240, E-
This increases efficiency of productivity & it provide safety
ISSN: 2319-2259, Vol. 5, Issue 1, Dec- Jan 2016, pp-1-14
of operator while handling of the material.
[10] Huqi wang et al, “Structural Analysis and Improvement
8. FUTURE SCOPE
of Large-scale Forklift's Wheel Rim”, Advanced Materials
The current system can be made automatic by powering Research, Vols. 712-715, 2013, pp 1080-1083
to wheel. And more heavy weight can be lift using bulky lead
[11] Baba Md Deros et al, “A Study on Ergonomic Awareness
among Workers Performing Manual Material Handling

© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1135
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 03 | Mar-2018 www.irjet.net p-ISSN: 2395-0072

Activities”, Procedia - Social and Behavioral Sciences,


Elsevier Ltd., Vol. 195, 2015, pp- 1666-1673

[12] Miroslava Kramarova, “Forklift workers strain of spine


at industrial logistics in depending on human work
posture”, Procedia Engineering Vol. 192, 2017, pp- 486 –
491

[13] Zhang kejun, “Research on Dynamic Optimization


Principles for Forklift Truck Mast”, Applied Mechanics
and Materials, Vols 556-562, 2014, pp 1147-1150

B) Books-

[1] R. S. Bridger, “Introduction to Ergonomics”, CRC press ,


3rd edition

[2] 2. V. B. Bhandari, “Design of Machine Element”, Tata


McGraw-Hill, 3rd edition, 2010.

[3] S. S. Ratan, Theory of Machine, Tata McGraw-Hill, 3rd


edition, 2009.

[4] B. L. Theraja, “Electrical Techonology”, S. Chand


Publications, 23rd edition

[5] Kalaikathir Achchagam, “Design Data- Data Book of


Engineers”, P.S.G. College of Technology, Coimbatore.

© 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1136

You might also like