REMOTE CONTROLLED SCREW JACK

Submitted in the partial fulfillment of the requirement for the award

DIPLOMA

IN MECHANICALENGINEERING

SUBMITTED BY:

1. S.BARANI
4. E.VIGNESH
2. S.MURALI
5. RAMAMOORTHY ANAND
3. N.S.VENKATESAN
6.
Under guidance of
Mr. N.MUTHUKUMAR
MARCH 2012
DEPARTMENT OF MECHANICAL ENGINEERING.

AMK TECHNOLOGICAL POLYTECHNIC COLLEGE

CHENNAI-602103

AMK TECHNOLOGICAL POLYTECHNIC COLLEGE

CHENNAI-602103

BONAFIDE CERTIFICATE
This is to certify that this Project work on

REMOTE CONTROLLED SCREW JACK

submitted by . Reg. No.

in partial fulfillment for the award of
DIPLOMA IN MECHANICAL ENGINEERING
This is the bonafide record of work carried out by him under our supervision during
the year 2012
Submitted for the Viva-voce exam held on ..

H.O.D.

INTERNAL EXAMINER

PROJECT GUIDE

EXTERNAL EXAMINER

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

At the outset, we would like to emphasize our sincere thanks to the Principal
Mr. R.J.KUMAR M.E for encouragement and valuable advice.

we thank our Esquired Head of Department Mr R.RAJKUMAR M.E for

presenting his felications on us.
We are grateful on our Entourages Mr. N.MUTHUKUMAR for guiding in
various aspects of the project making it a grand success.
We also owe our sincere thanks to all staff members of the MTMR and
FOUNDRY Department.

Ultimately, we extend our thanks to all who had rendered their co-operation
for the success of the project.

CONTENTS

CONTENTS
CHAPTER NO.

TITLE

1.

INTRODUCTION

2.

SYNOPSIS

3.

CONSTRUCTION

4.

WORKING PRINCIPLE

5.

PRINCIPLE OF DC MOTOR

6.

FORWARD AND REVERSE CONTROL

7.

DESCRIPTION OF RELAY CONTROL

8.

FEATURES OF MOTORISED JACK

9.

ADVANTAGES

10.

APPLICATIONS

11.

MECHANICAL SPARE PARTS DIAGRAM

12.

FINSIHING AND PAINTING

11.

COST ESTIMATION

12.

CONCLUSION

13.

BIBILOGRAPHY

INTRODUCTION

INTRODUCTION
This project concentrates on providing descriptions of all the basic operating
principles and design of screw jack..
In our technical education the project work plays a major role. Every student
is put in to simulate life particularly where the student required bringing his
knowledge, skill and experience of the project work.
It helps how to evolve specifications under given constrains by systematic
approach to the problem a construct a work device. Project work thus integrates
various skills and knowledge attainment during study and gives orientation towards
application.
As the students solve the various problems exposed by the project work, the
students get the confidence to overcome such problems in the future life. It helps in
expanding the thinking and alternatives for future applications.

SYNOPSIS

SYNOPSIS
In current situation , car tire is removed for repair work a jack is used and it
is operated now by manually and not so easy to handle by the driver. In this project ,
the screw jack unit is

placed under the chassis unit which can be lifted by

operating the hand held remote control .

This screw jack is operated by a DC motor which is coupled to the main
screw rod of jack unit. The power supply for this jack unit is taken from the battery
which is already available in the same vehicle.
. The electrical power from the battery

is given to electric motor through the

forward and reverse control relay with the help of two switches. One switch is used
for raising the chassis unit and the second switch is used for lowering the chase
unit.
Thus, by introducing this project

in the automobile vehicle dual

advantage is obtained . One is the easy and convenient to operate and the tire
removal work is simplified.

CONSTRUCTION

CONSTRUCTION
The projects consists of
1. M.S . BASE FRAME
2. SCREW JACK
3. 12 VDC MOTOR.
4. ELECTRIC RELAY PANEL
5. REMOTE CONTROL UNIT
6. CONTROLLER UNIT.

1. M.S . BASE FRAME

This unit is fabricated in a M.S. L angle material having the size of 25 x 25
x 3 MM (L X B X T) . The jack unit is mounted on this base frame. The screw jack
unit is fitted under this chase unit..

M.S BASE PLATE

3) SCREW JACK ASSEMBLY UNIT;

A jackscrew is a type of jack which is operated by turning a leadscrew. In the

form of a screw jack it is commonly used to lift heavy weights such as the
foundations of houses, or large vehicles.

4) 12 VDC Motor with built in speed reduction gear box;

This DC motor is shunt type 12V DC motor. This motor is having built in type
speed reduction gear box unit. It has high torque and low speed capacity. The
electrical supply to the motor is from 12 V DC battery. The DC Motor drives the
Jack mechanism. The Photo view of motor is shown below.

PRINCIPLE OF DC MOTOR
A DC motor is a dc machine working as a motor to convert dc electrical
energy into mechanical energy (dc) motor are very commonly used in cars, trucks,
aircrafts, etc. They are also used in large ratings, where wide range of speed control
is necessary.
When a conductor is carried a current and in lying in magnetic filed. Force
acting on the conductor. This is the principle of a Dc motor. The conductor is

housed in armature slots and current is applied from the dc source through brushes
and commutator. The field poles provide the magnetic field.

The construction of dc motor and generator are similar. However their

external appearance may be somewhat different. A motor has a rather closed frame
because it is may be operating in dusty environment and unskilled workers may be
working in its vicinity.

TYPES OF DC MOTOR
DC Shunt Motor:
This motor has medium starting torque, a speed regulation of 5 10 % and
excellent adaptability to adjustable speed service. It can be used for constant speed
drives like pumps, fans blowers, etc,. However for all these applications, a 3 phase
induction motor is preferable, because it ;is cheaper, more rugged and requires
lesser maintenance than dc motor. However a dc shunt motor is cheaper for low
speed drives. Moreover, whenever a wide range of speed control is required, dc
shunt motor is used. The main application of dc shunt motor is in steel and
aluminium, rolling mills and ward Leonard speed control system.

Dc Series Motor:

This motor has a very high starting torque. Moreover it speed decreases with
increase in load torque. So that its power input remains more or less constant. It is
best suited for hoist cranes and traction.

Speed control is generally obtained

through armature control. They are used for battery-powered vehicles.

Compound Motor:
A differential compound is rarely used. The characteristics of a cumulative
compounds motor depend on the relative strength of series and shunt fields. It has
good starting torque and dropping speed load characteristic. They can be used for
pulsating loads needing flywheel action, viz. shears, conveyors, crushers, hoists,
plunger pumps, etc., Whenever the supply voltage is likely to vary considerably, a
compound motor is preferred. Because its induction and contribution to back emf,
the series field helps in reducing the fluctuations of current drawn from mains.

RATINGS OF MOTOR
Motors are rated by their voltage, current draw, output speed, and torque.
Operating Voltage
Operating voltage specifies the nominal (normal) voltage the manufacturer
recommends for the motor. Most small DC motors are designed for 1.5 to 12 volt
operation, with the majority in the 3-6 volt range. Larger DC motors designed for
heavy-duty applications usually require 12 to 24 volts, with some needing upwards
of 90 volts. Often, but not always, the higher the voltage, the more powerful the

motor (this does not apply to stepper motors, where very low voltages on the
order of just a few volts are common for heavy-duty motors). Most motors can
be run at operating voltages higher or lower than the specified rating.

Lower voltages reduce torque and speed.

Higher voltages increase torque and speed.

(Note: For stepper motors, speed is not greatly altered by changing the voltage.)
Avoid applying excessively high voltages to a motor, or else it could overheat and
burn out. R/C servo motors contain their own electronics which are not designed for
use over about 7.2 volts.
Current Draw
Current draw is the amount of current, specified in milliamps or amps, that the
motor requires to produce a certain amount of torque. Motors consume different
amounts of current depending on how they are operated:

No-load. A motor that doesnt have anything attached to its shaft isnt doing
any work, and is said to be free-running. No-load current tends to be very low.

Load. As the motor does work, its load and current draw increases.
Manufacturers rate the current draw under load using different standards,
making it hard to judge a motor using this specification alone.

Stalled. When the motor shaft stops rotating, it stalls and draws as much
current as will flow through the windings. This specification is useful for
worst case scenario engineering planning.

Shorted. Maximum current flows into the motor when the coils are shorted
out. The motor will not run, and like any short circuit, if operated in this way
for any length of time, serious damage can result to other systems on the robot.

Torque
Torque is the way the strength of the motor is measured. It is typically calculated by
attaching a lever to the end of the motor shaft, and a weight or gauge on the end of
that lever. The length of the lever usually depends on the unit of measurement given
for the weight. Examples:

Metric measurements use Newton meters (Nm), kilograms-force meters

(kgf-m), or sometimes gram-centimeters (gm-cm).

Standard measurements use ounce-inches (oz-in), or pound-feet (lb-ft), or

pound-inches (lb-in). Its common to reverse the nomenclature and call it footpounds and inch-pounds.
Speed
The speed of the motor indicates how fast its shaft is turning. DC motors without a
gearbox spin at 3,000 to over 12,000 RPM (revolutions per minute). With a gear
box, the speed can vary from under 1 RPM, on up.
Stepping motors are not rated in RPM, but pulses (or steps) per second. The speed
of a stepper motor is a function of the number of steps required to make one full
revolution, times the number of steps applied to the motor each second. Typical
values are 200 or 300 PPS.

5) ELECTRIC RELAY PANEL .

RELAY:

SPECPCATION OF RELAY:
a) Nature of supply: dc
b) Coil voltage: 12v
c) No of NO and NC contacts: 1
d) No of poles: single pole double throw
e) Shape of contact point: flat
f) Contact point material: silver or silver alloy
g) Type of relay: electro dynamic

TRANSMITTER AND RECEIVER:

These miniature RF modules provide a cost effective high performance FM

radio data link, as either 315, 433.92 or 868 MHz. Manufactured using later
trimmed thick film creaming hybrid the modules exhibits extremely stable
electronic characteristics over an industrial temperature range.

These are no

adjustable components and ensure very reliable operation over time.

This transmitter and receiver pairs enables the simple implementation of a
data link at distances up to 5 meters in building and 25 meters open ground. These
transmitter and receiver modules are optimized for wireless transmission of encoded

data packets. To reduce development time and ensure reliability and security chips
from the RF solutions range encryption ICs can be used to encode and decode the
data.
These modules will suit one to one and multi node wireless links in
applications including car and building security,

inventory tracking, remote

industrial process monitoring and computer networking. Because of their small size
and low power requirements, both modules are ideal for use in portable, batterypowered applications such as hand-held terminals.

CIRCUIT DETAILS
1. Micro controller system
2. Interface Circuit for stepper motor
3. Power supply (230V A.C. to 12 V and 5V DC)
4. Key Board Circuit

MICRO CONTROLLER SYSTEM:

This system monitors the engine condition by using PIC 16F870 (28 pin IC
Package) micro controller. The pin details of micro controller are shown in figure.

The circuit diagram for this micro controller board is shown below,

MOTHER BOARD CIRCUIT DETAILS

in no 2&5.The pin no 1 is RESET switch..The INPUTS are connected to

port B .The OUTPUTS are connected to PORT C.6 MHZ crystal is
connected to pin no 9,10.

POWER SUPPLY 5V DC AND 12V DC;

A 12 0 v step down transformer is used to stepdown 230V AC to 12V

AC .This 12V AC supply is converted to 12V DC using four rectifier diodes. The
voltage from the rectifier section is regulated to 12V DC using 7812 IC . From 12V
DC the 7805 IC is used for

regulating 5V DC for the

microcontroller.
the power supply circuit is shown in fig.

INTRODUCTION:

power supply of

All the electronic components starting from diode to Intel ICs only work
with a DC supply ranging from +5V to +12V. We are utilizing for the same, the
cheapest and commonly available energy source of 230V-50Hz and stepping down,
rectifying, filtering and regulating the voltage.
STEP DOWN TRANSFORMER:
When AC is applied to the primary winding of the power transformer, it can
either be stepped down or stepped up depending on the value of DC needed. In our
circuit the transformer of 230V/15-0-15V is used to perform the step down
operation where a 230V AC appears as 15V AC across the secondary winding.
Apart from stepping down voltages, it gives isolation between the power source and
power supply circuitries.
RECTIFIER UNIT:
In the power supply unit, rectification is normally achieved using a solid state
diode. Diode has the property that will let the electron flow easily in one direction
at proper biasing condition. As AC is applied to the diode, electrons only flow
when the anode and cathode is negative. Reversing the polarity of voltage will not
permit electron flow. A commonly used circuit for supplying large amounts of
DCpower is the bridge rectifier. A bridge rectifier of four diodes (4 x IN4007) are
used to achieve full wave rectification.

Two diodes will conduct during the

negative cycle and the other two will conduct during the positive half cycle, and
only one diode conducts. At the same time one of the other two diodes conducts for

the negative voltage that is applied from the bottom winding due to the forward bias
for that diode. In this circuit due to positive half cycle D1 & D2 will conduct to
give 0.8V pulsating DC. The DC output has a ripple frequency of 100Hz. Since
each alteration produces a resulting output pulse, frequency = 2 x 50 Hz. The
output obtained is not a pure DC and therefore filtration has to be done.
The DC voltage appearing across the output terminals of the bridge rectifier
will be somewhat less than 90% of the applied rms value. Normally one alteration
of the input voltage will reverse the polarities. Opposite ends of the transformer
will therefore always be 180 degree out of phase with each other. For a positive
cycle, two diodes are connected to the positive voltage at the top winding.

FILTERING CIRCUIT:
Filter circuits which is usually capacitor acting as a surge arrester always
follow the rectifier unit. This capacitor is also called as a decoupling capacitor or a
bypassing capacitor, is used not only to short the ripple with frequency of 120Hz
to ground but also to leave the frequency of the DC to appear at the output. A load
resistor R1 is connected so that a reference to the ground is maintained. C1, R1 is
for bypassing ripples. C2, R2 is used as a low pass filter, i.e. it passes only low
frequency signals and bypasses high frequency signals. The load resistor should be
1% to 2.5% of the load.
1000f/25V : for the reduction of ripples from the pulsating

10f/25V

: for maintaining the stability of the voltage at the load side.

0.1f

: for bypassing the high frequency disturbances

BLOCK DIAGRAM FOR POWER SUPPLY

STEP DOWN

TRANSFORMER

BRIDGE

POSITIVE

RECTIFIER

CHARGE
CAPACITOR

5V
REGULATOR

MOTHER
BOARD

VOLTAGE REGULATOR:

DISPLAY
BOARD

12V
REGULATOR

RELAY

The voltage regulators play an important role in any power supply unit. The
primary purpose of a regulator is to aid the rectifier and filter circuit in providing a
constant DC voltage to the device. Power supplies without regulators have an
inherent problem of changing DC voltage values due to variations in the load or due
to fluctuations in the AC linear voltage. With a regulator connected to the DC
output, the voltage can be maintained within a close tolerant region of the desired
output. IC7812 and 7912 is used in this project for providing +12V and 12V DC
supply.

1.

5 TO 12 V DC DRIVE CARD

Here we have to drive the 12V DC load(MOTOR). The 5V signal

from the PIC 16F870 micro-controller is fed into the input of interface
circuit. SL100 transistor is used here for high speed switching purpose
and IRF 540N MOSFET is connected to the motor to handle the larger
current drawn by the motor.

WORKING PRINCIPLE

WORKING PRINCIPLE

The working principle of this MOTORISED JACK is explained in block diagram

230 V AC

Power supply
12 VDC

ELECTRIC RELAY
PANEL

JACK UNIT

12 V DC
MOTOR

This MOTORISED JACK

has one 12 VDC motor. This DC motor drive is

transmitted to the jack unit through the screw rod .. The vehicle tyre is lifted up and
down by pressing the switch in the panel board. The 12 V DC supply is supplied
from the 12 V DC motor. The vehicle is moved up slowly without any sack .

DESCRIPTION OF
SCREWJACK

DESCRIPTION OF SCREWJACK;

A jackscrew is a type of jack which is operated by turning a leadscrew. In the

form of a screw jack it is commonly used to lift heavy weights such as the
foundations of houses, or large vehicles.

Contents
A jackscrew operates this automotive scissors-jack.

Applications
A jackscrew's threads must support heavy loads. In the most heavy-duty
applications, such as screw jacks, a square thread or buttress thread is used, because
it has the lowest friction. In other application such as actuators, an Acme thread is
used, although it has higher friction.
The large area of sliding contact between the screw threads means jackscrews have
high friction and low efficiency as power transmission linkages, around 30%50%.
So they are not often used for continuous transmission of high power, but more
often in intermittent positioning applications.

Advantages
An advantage of jackscrews over some other types of jack is that they are selflocking, which means when the rotational force on the screw is removed, it will
remain motionless where it was left and will not rotate backwards, regardless of
how much load it is supporting. This makes them inherently safer than hydraulic
jacks, for example, which will move backwards under load if the force on the
hydraulic actuator is accidentally released.

Mechanical advantage
The mechanical advantage of a screw jack, the ratio of the force the jack exerts on
the load to the input force on the lever, ignoring friction, is

where
is the force the jack exerts on the load
is the rotational force exerted on the handle of the jack
is the length of the jack handle, from the screw axis to where the force is
applied

is the pitch of the screw threads; the distance between them.

However, most screw jacks have large amounts of friction which
increase the input force necessary, so the actual mechanical
advantage is often only 30% to 50% of this figure.

FEATURES OF
MOTORIZED JACK

FEATURES OF THE JACK

It is compact in size
electrical power consumption is less
It can be utilized at our work shop
It is simple in construction

 Low cost
Less weight and easy to handle
It reduces the man power
It is compact in size.

ADVANTAGES

ADVANTAGES
Comfort to the driver
The tyre can be removed without much more effort
This jack operation is simple.
The current consumption is very low
Simple in construction and easy maintained

 It is compact in size and less weight

It is easy to operate with out hands-on training

APPLICATION

APPLICATION
It can be used as chase lifting system.
It is used in light vehicle l.
It is used in automatic remote control application by adding microcontroller
circuit..

MECHANICAL SPARE
PARTS DIAGRAM

FINISHING AND PAINTING

FINISHING AND PAINTING

JOB PREPARATION;
Before welding, remove any bend in the L angle with the sludge hammer on the
anvil block. Then it is cut to the required length with the hacksaw blade and
fabricated to required dimensional shape with arc welding.
FINISHING OPERATION BEFORE PAINTING;

After welding, any slag on the welded area is removed with the chipping hammer
and cleaned with the metal wire brush. Then all the surfaces are rubbed with the
emery sheet.

Metal primer is applied on the surfaces with the brush .After drying the metal
primer, the second coating is applied with the paint.

COST ESTIMATION

COST ESTIMATION

1.

JACK unit

700.00

2.

12 V DC Motor

1000.00

3.

REMOTE CONTROL UNIT

800.00

4.

M.S. FRAME

5.

Relay 2 Nos

600.00
-

600.00

6.

CONTROLLER UNIT

1800.00

7.

PUSH BUTTONS & WIRES

200.00

8.

MOTOR COUPLER UNIT

300.00

9.

METAL PRIMER

100.00

--------------6000.00
-------------------

CONCLUSION

CONCLUSION
We make this project entirely different from other projects. Since concepts
involved in our project is entirely different that a single unit is used to various
purposes, which is not developed by any of other team members.

By doing this project work, we understood the working principle and uses of
relay,screwjack and DC motor etc.,
.

Once again we express our sincere thanks to our staff members.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. A course in Automobile Technology

R.S. Khurumi

2. Electrical Technology

B.L. Theraja

3. Automobile Technology

R.S. Khrumi

www.google.com

PHOTO VIEW