Design and fabrication of car parking system th esis
1. Project Report
On
“Battery operated forklift”
In partial fulfillment for the award of the degree of
Bachelor of Technology
in
Mechanical Engineering
Submitted by
Anand kr. Yadav (BT-100140207)
Priyank singh (BT-100140243)
Shashikant satyarthi (BT-100140250)
Rajkumar (BT-100140247)
Virendra yadav (BT-100140256)
Under the guidance of
Er. Amit Poonia
(Asst. Prof. ME department)
SUBMITTED TO
SIR CHHOTU RAM INSTITUTE OF ENGINEERING &
TECHNOLOGY
CCSU CAMPUS, MEERUT
SESSION (2014 -18)
2. Certificate
This is to certified that Anand kr yadav(BT- 100140207),Sashikant
satyarthi(BT-100140250),Rajkuamr (BT-100140247),Priyank singh(BT-
100140243), Virendra yadav(BT-100140256)has carried out the project work
presented in this report entitled “Battery operated forklift system” for the
award of Bachelor of Technology in the stream of Mechanical Engineering
from S.C.R.I.E.T.,CCSU MEERUT under guidance of Er. Amit puniyaThe
thesis embodies results of work, and studies are carried out by the student
himself and it is an authentic report.
Project Guide Head of Department
Er. Amit Poonia Er. D.P. Singh
(Asst. Prof) (HOD of Dept.)
Department of M.E Department of M.E
SIGNATURE OF EXTERNAL EXAMINER
3. GUIDELINES FOR PREPARING THE THESIS
ARRANGEMENT OF THE CONTENTS OF THESIS
The sequence in which the thesis contents should be arranged and bound should
be as follows:
1 1. Cover Page and Title Page
2 2. Certificate (Bond Paper)
3 3. Abstract
4 4. Acknowledgements
5 5. Table of Contents
6 6. List of Tables
7 7. List of Figures
8 8. List of Symbols, Abbreviations and Nomenclature
9 9. Chapters
9.1 Chapter1. Introduction
9.2 Chapter 2. Literature review
9.3 Chapter3. Scope of the work
9.4 Chapter 4. Design Analysis
9.5 Chapter 5. Results and discussions
9.6 Chapter 6. Conclusions
10 10. References
11 11. Appendices
Abstract
4. In today's life, there is a wide variety of forklifts, from the large heavy loading
truck to the one that works among narrow aisles. Forklifts have become one
of the basic transportation tools we use in our lives. With all the forklifts in
existance, we find that there are some improvements that can be made to
bring the forklift to a better performance.
Existing forklift design has its limitation in rotation and the structure has
potential safety risk. Our new design has 180 degrees rotating forks attached
to truck body on both ends. Also, it has a scissor lift under the operator’s
cabin which improves the stability. There are two subassemblies: scissor lift
and lifting fork; there is a total of 37 parts in the new design.
Once the design is conceived, we calculate the mass properties of parts and
subassemblies to ensure the stability of the forklift. Results show that the
truck is safe to use: its center of gravity remains in the safety triangle and we
use this to get the maximum loading capacity. Then we run stress analysis on
important parts and subassemblies using finite element method (FEM).
Results show that the new design is safe to use under working conditions.
5. Acknowledgement
We express our deep sense of gratitude to Er. D.P. Singh , HOD, Mechanical
Engineering Department, for giving us opportunity to carry out this project.
With immense pleasure we express our deep sense of gratitude and respect to
Er. Amit Poonia (lecturer) who was guiding us by giving his valuable
suggestions, constructive criticism and encouragement, which helped us to keep
our spirits high and to deal with problems. His meticulous methodology, critical
assessment and warm encouragement made it possible for me to bring the work
in its present shape.We are sincerely thankful to all workshop and lab co-
ordinators, for giving us time to time support in doing this project. Finally, we
thank God for giving us the loving siblings and affectionate parents .Who
blessed us with everything all throughout our life. Our gratitude to them cannot
be expressed in words. To them we owe our wonderful today and a dream filled
tomorrow.
6. 12 Table of Content
13
CERTIFICATE 1-2
DECLARATION 3
ABSTRACT 4
ACKNOWLEDGEMENT 5
CHAPTER 1: INTRODUCTION 9-12
• THEORY 10
• NEED 11
• EASE OF USE 12
• WORKING 12
CHAPTER 2: LITERATURE SURVEY 13-16
CHAPTER 3: DESIGN AND FABRICATION OF CAR PARKING
SYSTEM 17-30
• COMPONENTS USED IN THE PROJECTS
1. DC MOTOR 18-19
2. CONTROLLER 20
3. PARKING SLOT 21
4. BELT 22
5. PULLEY 22-23
6. LIFT 23-24
7. NUTS AND BOLTS 25
8. SCREW 26
9. TRACK 27
10. SOLID CIRCULAR ROD 28
11. WOODEN BLOCK 28
12. SOLAR PANEL 29
13. BATTERY 30
• MANUFACTURING PROCESS USED IN THE PROJECT 31-33
1. WELDING
2. DRILLING
7. CHAPTER: 1
INTRODUCTION
Introduction
1.1 Overview
Because of the varieties, different shapes, different packaging
of the goods, loading and unloading has always been a heavy
process during transportation. Forklifts were naturally
invented and became the solution to this problem; they save
time and space. If cargos are being organized properly, the
use of forklifts with the right attachments would be the best
way to load and unload, which would make the whole process
8. less time consuming and less labor intensive. In addition,
forklifts optimize the use of storage space by eliminating the
need for many people to handle the loading and unloading
operations and enabling the stack-up of goods. The stacking
height of goods can be up to 4~5m, some even can be as high
as 10m, which brings up the utilization of warehouse by least
40%. Now, most of the transportation operations are using
forklifts.
Forklifts fall under the category of lifting and transport
machinery. A forklift has a lifting system for loading
packages and a mobile system for moving around, like a
truck. A forklift is also called a forklift truck. It is mainly used
for loading and unloading common packaged goods. With
some special attachments, it can also be used for non-
packaged goods or untraditional shaped good. Figure 1.1
shows a forklift equipped with
9. attachment picking up a roll of paper. This hydraulic clip
attachment allows the operator to open and close a clip around
a load. Products like cartons and boxes can use this type of
attachment. Figure 1.2 shows a forklift with a special
attachment allowing the rotation of the load.
Figure 1.1 Forklift with Paper Handling Chassis [1]
Figure 1.2 Hyster Forklift Trucks Equipped with Heavy Duty Vista Masts [2]
10. HISTORY OF FORKLIFT
Just like many other inventions, the forklift was born out of necessity.
The two-wheel hand operated forklift first appeared over one hundred
years ago. These original units were wrought- iron axle and cast iron
wheels which enabled loads to be lifted and transported without manual
labor. In the early 1900s the evolution to combine horizontal and vertical
motion resulted in the first hand operated forklift capable of lifting a few
inches of the ground. And with this the development of the forklift are on
fastrack till today.
In 1917 the Clark Company, manufacturers of axles, created a truck
called the Tructractor to move materials around their factory. As people
visited the factory and saw the Tructractor at work they placed orders
from Clark to build Tructractors for their companies. A few years later the
first hydraulic powered lift was added to some trucks to give them lifting
power. In 1923, Yale was the first company to use forks that lifted loads
off the ground and an elevated mast that could extend beyond the height
of the truck. The Yale truck is considered to be the first forklift.
A few developments helped the forklift to increase in production
including the introduction of the standardized pallet in 1930 and World
War II. Both of these developments increased production of forklifts and
allowed distributors the means to efficiently move heavy loads.
11. Industries Corporation is No. 1 among all the industrial lift truck
suppliers. It has 11 categories of forklifts, from hand pallet trucks
to counterbalanced trucks, from electronic to engine powered,
including more than 50 different types of forklifts. Each one of
them can be ordered with different capacity and loading range to
meet different needs. The loading capacity is from 0.75 ~ 8.5t.
The maximum lifting height can be up to 14.8 meter [4].
Right now, all forklifts’ forks are attached to the truck on one
end, and the lifting system use chain or cable. We feel like there
are some improvements can be done, and we will focus on these
two features in the rest of the research.
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13. LITERATURE SURVEY OF THE DESIGN AND FABRICATION
OF CAR PARKING
The concept for the automated parking system was and is driven by two factors: a
need for parking spaces and a scarcity of available land. The earliest use of an APS
was in Paris, France in 1905 at the Garage Rue de Ponthieu . The APS consisted of
a groundbreaking multi-story concrete structure with an internal elevator to
transport cars to upper levels where attendants parked the cars. In the 1920s, a
Ferris wheel-like APS (for cars rather than people) called a paternoster system
became popular as it could park eight cars in the ground space normally used for
parking two cars. Mechanically simple with a small footprint, the paternoster was
easy to use in many places, including inside buildings. At the same time, Kent
Automatic Garages was installing APS with capacities exceeding more than a
1,000 cars. The first driverless parking garage opened in 1951 in Washington,
D.C., but was replaced with office space due to increasing land values.
APS saw a spurt of interest in the U.S. in the late 1940s and 1950s with the
Bowser, Pigeon Hole and Roto Park systems. In 1957, 74 Bowser, Pigeon Hole
systems were installed, and some of these systems remain in operation. However,
interest in APS in the U.S. waned due to frequent mechanical problems and long
waiting times for patrons to retrieve their cars. In the United Kingdom, the Auto
Stacker opened in 1961 in Woolwich, south east London, but proved equally
difficult to operate. Interest in APS in the U.S. was renewed in the 1990s, and there
are 25 major current and planned APS projects (representing nearly 6,000 parking
spaces) in 2012.The first American robotic parking garage opened in 2002 in
Hoboken, New Jersey. While interest in the APS in the U.S. languished until the
1990s,Europe, Asia and Central America had been installing more technically
advanced APS since the 1970s.[3] In the early 1990s, nearly 40,000 parking spaces
were being built annually using the paternoster APS in Japan. In 2012, there are an
estimated 1.6 million APS parking spaces in Japan. The ever-increasing scarcity of
available urban land (urbanization) and increase of the number of cars in use
(motorization) have combined with sustainability and other quality-of-life issues to
renew interest in APS as alternatives to multi-story parking garages, on-street
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14. parking and parking lots. Currently the biggest APS in Europa is in Aarhus
(Denmark) and provides 1000 parking spaces via 20 car lifts.
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17. DESIGN AND FABRICATION OF CAR PARKING
A) COMPONENTS USED IN THE PROJECTS
3. A.1: 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 type widely used, since 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. The universal motor can operate on direct current but is a
lightweight motor used for portable power tools and appliances. Larger DC motors
are used in propulsion of electric vehicles, elevator and hoists, or in drives for steel
rolling mills. The advent of power electronics has made replacement of DC motors
with AC motors possible in many applications. DC Geared motors with robust
metal gear box for heavy duty applications, available in wide RPM range and
ideally suited for robotics and industrial applications. Very easy to use and
available in standard size. Nut and threads on shaft to easily connect and internal
threaded shaft for easily connecting it to wheel. Robokits India High Precision
Quad Encoder Geared DC Motor 12V 1000RPM [RMCS-2299] - DC motor with
quad encoder and gear box for High torque, High precision, 168 Counts per
Revolution. 1000 RPM Movement speed at 12V no load. Encoder Motor Features:
Motor with Quad encoder which also gives direction of
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19. 3.A.2: CONTROLLER- A motor controller is a device or group of devices
that serves to govern in some predetermined manner the performance of an
electric motor. A motor controller might include a manual or automatic
means for starting and stopping the motor, selecting forward or reverse
rotation, selecting and regulating the speed, regulating or limiting the torque,
and protecting against overloads and faults.
• Fig. 3.2 Controller
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20. 3.A.2: Parking Slot- A parking space is a location that is designated for parking,
either paved or unpaved. It can be in a parking garage, in a parking lot or on a city
street. The space many be delineated by road surface markings.
• Fig. 3.3 Parking slot
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21. 3.A.4: Belt -Conveyor belts can be miles and miles long or less than a half-meter.
They move tons or gram fast or slow…continuously or intermittently people,
products, groceries, mail, sushi, sand, cars and much more. The basic conveyor
belt system consists of two pulleys (or drums) with a continuous belt running
between them.
• Fig. 3.4 Belt
3.A.5 : Pulley:- A pulley is a wheel on an axle or shaft that is designed to support
movement and change of direction of a taut cable or belt, or transfer of power
between the shaft and cable or belt. In the case of a pulley supported by a frame or
shell that does not transfer power to a shaft, but is used to guide the cable or exert a
force, the supporting shell is called a block, and the pulley may be called a sheave.
A pulley may have a groove or grooves between flanges around its circumference
to locate the cable or belt. The drive element of a pulley system can be a rope,
cable, belt, or chain. Hero of Alexandria identified the pulley as one of six simple
machines used to lift weights .Pulleys are assembled to form a block and tackle in
order to provide mechanical advantage to apply large forces. Pulleys are also
assembled as part of belt and chain drives in order to transmit power from one
rotating shaft to another.
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22. 3.A.5: Lift -A fluid flowing past the surface of a body exerts a force on it. Lift is
the component of this force that is perpendicular to the oncoming flow direction. It
contrasts with the drag force, which is the component of the force parallel to the
flow direction. Dynamic lift is distinguished from other kinds of lift in fluids.
Aerostatic lift or buoyancy, in which an internal fluid is lighter than the
surrounding fluid, does not require movement and is used by balloons, blimps,
dirigibles, boats, and submarines. Planing lift, in which only the lower portion of
the body is immersed a liquid flow, is used by motorboats, surf boards.
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23. Fig. 3.5 Lift
3.A.6 : Nuts and bolts- A nut is a type of fastener with a threaded hole. Nuts are
almost always used in conjunction with a mating bolt to fasten multiple parts
together. The two partners are kept together by a combination of their threads'
friction (with slight elastic deformation), a slight stretching of the bolt, and
compression of the parts to be held together. A bolt is a form of threaded fastener
with an external male thread. Bolts are closely related to, and often confused with.
Bolts are often used to make a bolted joint. This is a combination of the nut
applying an axial clamping force and also the shank of the bolt acting as a dowel,
pinning the joint against sideways shear forces. For this reason, many bolts have a
plain unthreaded shank (called the grip length) as this makes for a better, stronger
dowel.
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24. Fig. 3.6 Nuts and Bolt
3.A. Screw:- A screw is a type of fastener, sometimes similar to a bolt (see
Differentiation between bolt and screw below), typically made of metal, and
characterized by a helical ridge, known as a male thread (external thread) or just a
well thread. A screw is an inclined plane wrapped around a nail. Other screw
threads are designed to cut a helical groove in a softer material as the screw is
inserted. The most common uses of screws are to hold objects together and to
position objects. A screw will usually have a head on one end that contains a
specially formed shape that allows it to be turned, or driven, with a tool. Common
tools for driving screws include screwdrivers and wrenches. The head is usually
larger than the body of the screw, which keeps the screw from being driven deeper
than the length of the screw and to provide a bearing surface. The cylindrical
portion of the screw from the underside of the head to the tip is known as the
shank; it may be fully threaded or partially threaded.The distance between each
thread is called the "pitch".
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25. 3.A.11: BATTERY :- An electric battery is a device consisting of one or
more electrochemical cells with external connections provided to power
electrical devices such as flashlights, smartphones, and electric cars. When a
battery is supplying electric power, its positive terminal is the cathode and
its negative terminal is the anode.The terminal marked negative is the source
of electrons that when connected to an external circuit will flow and deliver
energy to an external device. When a battery is connected to an external
circuit, electrolytes are able to move as ions within, allowing the chemical
reactions to be completed at the separate terminals and so deliver energy to
the external circuit. It is the movement of those ions within the battery which
allows current to flowout of the battery to perform work.
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26. Fig. 3.11 Battery
(B) MANUFACTURING PROCESS USED IN THE PROJECT
3.B.1 WELDING :- Cast iron can be welded perfectly well using a stick welder
and nickel rods, or with preheating by a gas welder using cast iron rod. Welding
cast iron is a precision task that requires high heat, and often expensive equipment.
You should not attempt it on the strength of reading a brief Internet article, no
matter how informative. However, understanding the basics can help you prepare
26
27. for a qualification course, or to make better decisions for welding projects run by
qualified personnel under your supervision.Always preheat or precool cast iron
using the same method throughout. Changing methods can cause stress and
fractures in the cast iron. These may ruin your project, or be small enough to go
unnoticed until the iron fails catastrophically during normal operation.Cast iron is
typically higher in carbon than steel. This makes the iron brittle, and more difficult
to weld than other industrial metals.
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29. WORKING:- The multilevel car parking use to park large number of cars. A
multilevel car parking system is a electromechanical system designed to minimize
the area for parking cars. We used belt, pully and roller which is operated manually
using different switch.It is controller by a controller switch.first key work to pully
upward and backword. Second key work like lift reciprocate upword and
downword. Third key is rotate lift on right side and left side another key is work
like rotate upword and backword that is working of design and fabrication of car
parking system.
4.A: PARKING SLOT- A parking space is a location that is designated for
parking, either paved or unpaved. It can be in a parking garage, in a parking lot or
on a city street. The space many be delineated by road surface markings.
Fig. 4.1 Saving Slot
29
30. 4.Parking Space :- A parking space is a location that is designated for parking,
either paved or unpaved. It can be in a parking garage, in a parking lot or on a city
street. The space many be delineated by road surface markings. The automobile
fits inside the space, either by parallel parking, perpendicular parking or angled
parking. Depending on the location of the parking space, the time allowed to park
may be fixed by regulation, and a fee may be required to use the parking space. It
may be designated for free parking. When the demand for spaces outstrips supply
vehicles may overspill park onto the sidewalk, grass verges and other places which
were not designed for the purpose.
4.2 Saving space
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32. DESIGN AND ANALYSIS
The machine is practically developed, observations are made and to improve its
performance theoretical calculations are made.
Assuming weight of car = 0.5 kg
weight of lift = 1.65 kg
Total weight = 2.15 kg
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34. CHALLENGES
• An alternative to manual parking.
• Controller and lift motions.
• Need skilled people for control.
• Time-consuming,uncompensated labor limits and educational opportunity.
• Lack of technological improvements for worker.
1
2
PROBLEM STATEMENTS
Parking in society parking by control manually, but the controller and lift motion
effect to their parking, and the motion of controller and lift need educational
worker. Our goal is to design an inexpensive and durable design and fabrication of
car parking system for use in urban areas to gently car parking. Due to cost
constraints, the parking space is to be shared among several families or can be used
by a car park in no parking area. The car parking area by manually must be easy to
build,setup and maintain locally with local materials, easy to operate (minimal
required steps), and easy to power by solar panel. It must also be more comfortable
to use than manual methods and culturally acceptable in society.
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36. APPLICATIONS OF THE DESIGN AND FABRICATION OF
CAR PARKING SYTEM
14
15
• It is very useful in the high population density in urban area.
• This whole arrangement will be used as an exercise equipment.
• Easy to operate and less effect of electricity by manual using.
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38. ADVANTAGES
Efficiency: - It is much more efficient to wash clothes using the design and
fabrication of car parking than to use the manual car parking. The parking slot
whereas each car must be parked individually in the parking slot. It also requires
less area when compared to normal parking space. The automated car parking is
need high electricity and maintenance can be replace by manual car parking system
because it rotates continuously without changing concept.The operator does not
need well skilled worker for operate controller.
The manual parking is also more comfortable to use than the automated car
parking. The controller does not need to lean over the car parking. Instead,the
operator sits on the controller and lift most of the time.It only needs get up to load
the machine, change automated to manual parking. This leaves traffic free to urban
area keeps them out of the harmful effect of car.
Affordability: - A natural location to install a Praking slot is at the public area can
park anyone. The urban people already use the parking area and they will be able
to Understand whole thing that is car parking system share the parking space
among the entire community. With a common car parking, an individual small
scale parking space will not need spend a large sum of money for a small car
parking system. Those who would not normally be able to afford such a device
would be able to use one for free or for a small fee. A car parking is also
inexpensive to operate because the user does not need to pay for power. This is
especially important in places where electricity is extremely expensive. We have
minimized the use of other materials like angle iron and wood to reduce the cost to
the end customer.
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39. Easy to Build and Maintain: - Unlike any of the other alternatives, the car
parking uses locally available no. of car. It can be produced in any area that has
prevalent paking technology and things like wood, cast iron and belt. Since the
parts are widely available, the parking slot can serve as a basis for local
entrepreneurs to start micro enterprises which would stimulate the local economy.
Another advantage of using locally available parts is that the car parking is easy to
repair. It is mechanically simple enough that any manual parking repair would be
able to service the less skilled of worker.
DISADVANTAGES
• Need much human effort.
• It is heavy in weight.
• Structure is complex.
• Children can’t use it.
1
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41. CONCLUSION
The machine must be inexpensive and easy to build if it will be adopted into the
community.We recognized this need and designed the machine from the start with
low cost in mind. The machine will only contain parts that are readily available in
urban areas. This eliminates the need to order or import components just for the car
parking. The machine also uses lift and controller parts for all the precision parts.
These parts are very inexpensive because urban areas have a surplus of unused
parking space. The solar panel energy car parking is quite different from the
community’s current method of automated car parking; the community may be
reluctant to try the new parking space. To help encourage the adoption of the car
parking, we will run multiple number of car park with small area so we can adjust
the design to meet their needs. We will run the trial periods with groups like the
parking of car cooperative who are already familiar with park powered machines;
they have already proved they are willing to try new technologies. If parking in the
cooperative accept and use the machines, then they will serve as spokes-people for
the new machine in their local community. Their support will greatly increase the
credibility of the machine so that local people will be willing to try it. We
achieved what we desired i.e. to build a manually driven car parking powered low
cost car parking space using locally available materials and performing necessary
function of park number of car park and rinsing with ease. Our manual car parking
system doesn’t consume more electricity compare to automated car parking
system. The car parking can be used by the urban people also while workout and exercises. It
can simple purposes car parking. While car parking, the number of car park can be park utilizing
the parking slot by using manual car parking. If the production of this car parking is
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42. done at commercial scale then the total production cost of the machine can be
reduced to 40% of estimated cost.
1
2
3
4
5
6
7 CHAPTER: 11
8 REFERENCES
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• R.S.Khurmi “Design of Machine Elements”, Eurasnia publishing house 3 Pvt
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• Bruzzone, M. & Wieler, A. (2010) “Reflecting on an Intercultural Design-Build
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