DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING

Integrated Automobile Jack

System (IAJ)

Phil Bailey
Michael Rainey
Lorenz Schmid
Matthew Waldorf
Spring 2016
Instructor : Kevin Russell

Abstract
When it comes to automobile repairs, a flat tire is an elementary problem to address.
However, when a flat tire occurs while driving on a busy street as it often does, several problems
arise. Firstly, not everyone knows the correct position to place a jack. If the jack is not placed
under a sturdy enough part of the chassis, raising the jack can damage the vehicle or even result
in injury to the jack operator. Secondly, doing anything on the side of a highway is a dangerous
task, especially if it requires your back to be turned to the roadway. The Integrated Automobile
Jack (IAJ) has been designed to remove the necessity of having a technical background to
change a tire as well as reduce the time spent on the side of the roadway while performing a
dangerous tire change.
The IAJ is a prefabricated system implemented into the manufacturing stage of the
vehicle. The vehicle owner does not have to pay additional costs for components or installation,
as the new vehicle will already be equipped with the IAJ. Each of the four bottle jacks are
connected to the brake system and mounted behind each tire. When the system is engaged,
pumping the brakes pressurizes the front or rear bottle jacks which consequently raises the front
or rear of the car. This is further explained in section 2. In section 4, the new components
including a newly designed bottle jack, a valve box, and electronic isolation valves are
implemented into the vehicle. A system like this improves the safety and efficiency of
performing elementary maintenance.

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Table of Contents

Abstract ......................................................................................................................................................... 2
Table of Contents .......................................................................................................................................... 3
List of Figures and Tables............................................................................................................................. 4
Introduction ........................................................................................................................................... 5

1.

1.1 Project Goal and Background.............................................................................................................. 5

1.2 Previous Technology ........................................................................................................................... 5
2.

Design Solution ................................................................................................................................... 11

3.

Design Analysis .................................................................................................................................. 14

4.

Design Components ............................................................................................................................ 23

4.1 Brake lines ......................................................................................................................................... 23
4.2 System Controller and Circuitry ........................................................................................................ 24
4.3 Electronic Isolation Valve .................................................................................................................. 25
4.4 Jack Design ........................................................................................................................................ 25
4.4.1 Bracket System .......................................................................................................................... 26
4.4.2 Jack Valve Box .......................................................................................................................... 27
4.4.3 Stabilizing Foot .......................................................................................................................... 29
4.4.4 Seals ........................................................................................................................................... 29

5.

Conclusion .......................................................................................................................................... 30

6.

References ........................................................................................................................................... 32

Apendix ....................................................................................................................................................... 35

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List of Figures and Tables

Figure 1 - US3918683 [5] ............................................................................................................................. 6
Figure 2 Pascals Law [6] .......................................................................................................................... 6
Figure 3 Types of Jacks ............................................................................................................................. 7
Figure 5 Hydraulic Jack Extending [7] ...................................................................................................... 8
Figure 4 Hydraulic Jack Retracting [7] ...................................................................................................... 8
Figure 8 Vacuum Booster in Use [11] ....................................................................................................... 9
Figure 6 Hydraulic Power Brake System [9] ............................................................................................. 9
Figure 7 Modern Hydraulic Power Brake System [10] ............................................................................. 9
Figure 9. Recreational Camper Stabilization [13].................................................................................... 10
Figure 10. Jack Placement ....................................................................................................................... 11
Figure 11 System Schematic .................................................................................................................... 12
Table 1: Bill of Materials ............................................................................................................................ 13
Figure 12 and 13: Weight distribution in common cars [14] [15] .............................................................. 14
Figure 14 Brake Pressure Analysis .......................................................................................................... 16
Figure 15 Static Structure ........................................................................................................................ 16
Figure 16 Jack Safety Factor.................................................................................................................... 17
Figure 17 Foot Structure .......................................................................................................................... 18
Figure 18 Pin Safety Factor ..................................................................................................................... 18
Figure 19 Lower Extension Safety Factor ............................................................................................... 18
Figure 20 Upper Extension Safety Factor ................................................................................................ 18
Figure 21 Housing Safety Factor ............................................................................................................. 19
Figure 22 Overall Jack Stress .................................................................................................................. 19
Figure 23 Foot Stress ................................................................................................................................ 20
Figure 24 Lower Extension Stress ........................................................................................................... 20
Figure 25 Upper Extension Stress............................................................................................................ 20
Figure 26 Housing Stress ......................................................................................................................... 20
Figure 27 Pin Stress ................................................................................................................................. 21
Table 2: Values of Factor of Safety and von-Mises Stress ......................................................................... 21
Table 3: Volume of Jack ............................................................................................................................. 22
Figure 28 Brake Line Cut-away [17] ....................................................................................................... 23
Figure 29 System Controller Schematic .................................................................................................. 24
Figure 30 Electronic Isolation Valve [18]................................................................................................ 25
Figure 31 Extended Jack and Compressed Jack ...................................................................................... 25
Figure 33 C Channel ................................................................................................................................ 26
Figure 32 Locking Collar ......................................................................................................................... 26
Figure 34 Valve Jack Box ........................................................................................................................ 27
Figure 35 Check Valve [19] ..................................................................................................................... 27
Figure 36 Release/Screw Valve [20] ....................................................................................................... 28
Figure 37 Flow Schematic ....................................................................................................................... 28
Figure 38 Stabilizing Foot........................................................................................................................ 29
Figure 39 U-cup Seal ............................................................................................................................... 29

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1. Introduction
1.1 Project Goal and Background
Modern automobiles are composed of many mechanical and electrical systems. One of
the most common failures is a flat tire [1]. In order to fix this on the road side, a driver needs to
exit there vehicle and retrieve a jack usually located in the trunk of the car. This jack then needs
to be placed safely on a sturdy structure near the affected tire and used to raise the automobile.
The tire then needs to be changed and the car safely back lowered down, and the tools placed
back into the automobile. The main problem with this method is the complexity of returning the
vehicle to operating conditions from such a common failure. Wrongful placement of the jack can
lead to serious damage to the car. Not only can it be used for tire changes but other word done on
the underbody of a vehicle such as an oil change. Additionally, working on a car on the side of a
busy street can be very dangerous. According to the governments Fatality Analysis Reporting
System encyclopedia, about 4,000 pedestrians are struck and killed each year. [2]. The
Integrated Automobile Jack System (IAJ) will bring this number down and make changing tires
on the side of the highway safer by reducing the time spent outside of the vehicle.
1.2 Previous Technology
Hydraulic Jack
Invented in 1851 by Richard Dudgeon, the hydraulic jack was originally created to make
working on horse carriages easier [3]. In the past, there have been attempts to integrate a
hydraulic jack into a car, such as the idea in patent US3918683 shown in figure 5 which uses the
cars power to drive a separate electric motor which operates a hydraulic pump, but there has
never been a design that does not require a separate system from the car (pump, compressor,
etc.).
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A hydraulic jack works on the basis of

Pascals Principle which states the pressure
in a closed fluid system/container is the same
at all points. Pressure is equal to the force
being applied divided by the area. Take a
system made up of a small cylinder
connected to a larger cylinder for example; if
pressure is applied to the smaller cylinder, a
given pressure arises within the system.
According to Pascals Principle, this pressure
is the same throughout the system [4].
However, because the surface area of the
Figure 1 - US3918683 [5]

larger cylinder is greater than that of

the smaller system, the force emitted
by the larger cylinder will be greater
as shown in figure 2 and equation 1.

Figure 2 Pascals Law [6]

1 = 2

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1 2
=
1 2

(. 1)

Scissor Jack
The scissor jack is another previous technology used to lift automobiles. A scissor jack
utilizes a threaded screw to utilize mechanical advantage. Scissor jacks are fairly lightweight,
simple and compact compared to hydraulic jacks, and therefor are the most commonly found in
automobiles for roadside repairs. When operating a scissor jack to raise an automobile, the user
must first place the jack directly under a sturdy point
on the undercarriage of the car. If not placed
correctly, a scissor jack can cause severe damage to a
vehicle. Once placed correctly, the user must attach a
crank handle to the end of the screw thread on the
scissor jack. Finally, the vehicle can be raised by
turning the crank. To lower the jack, the user simply
turns the crank the opposite way.
Floor Jack
Figure 3 Types of Jacks

A floor jack is a large and heavy hydraulic jack which

is not typically used for road side repairs due to its size. In addition to their large weight and size,
floor jacks also require a large lever arm to operate. Similar to scissor jacks, if a floor jack is
placed incorrectly under a vehicle it most likely will cause damage. For these reasons, floor jacks
are not the optimal solution. The three jack types are shown in figure 3.
Most manual hydraulic jacks operate the same way as a reciprocating pump. As the lever
of the jack is depressed the pressure in the system increases, which raises the jack and maintains
the height from the last pump. This is possible because of a series ball valves in the system. A

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ball valve has a ball bearing seated on a seal in a pipe which is slightly larger than the pipes
diameter to allow the flow to be completely sealed off. When a lever is lowered by the user (fig.
5), valve 1 is forced closed while valve 2 is forced open. This allows the working fluid to flow
through into the jack cylinder and subsequently raise the jack. When the user raises the lever (fig.
4), valve 1 is opened due to a vacuum pressure created from the lever raising which allows fluid
from the reservoir to flow and when the user lowers the lever (fig. 5), that fluid is pushed into the
cylinder. While valve 1 is open, valve 2 is closed due to the vacuum pressure generated. With
valve 2 closed, this maintains the amount and pressure of fluid inside the jack cylinder, therefore
keeping the jack stable.

Figure 4 Hydraulic Jack Retracting [7]

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Figure 5 Hydraulic Jack Extending [7]

Power Braking System

The braking system on automobiles is
designed using a hydraulic system. It works by
compressing the brake pedal which pumps fluid
from the master cylinder to the slave cylinder.
Most modern cars now have two master cylinders
in tandem just in case one fails. However, the first

Figure 6 Hydraulic Power Brake System [9]

automobiles did not incorporate hydraulic brakes.

Instead, a mechanical system which included a lever and
a drum (expanding springs and a shoe) were used. There
systems were not efficient but they worked. It was not
until the 1920s that a hydraulic braking system was
developed by Lockheed Martin and placed on production

Figure 7 Modern Hydraulic

Power Brake System [10]

cars by Duesenberg. Figure 6 shows what a typical

hydraulic brake system of the time looked like. A modern
day braking system show in figure 7 uses a system almost
identical this, with the addition of a vacuum booster. The
vacuum booster increases the force generated by the driver
by at least 1.52 times. The booster utilizes a pressure
differential created by either the cars own engine, or what is
becoming more common, an electric motor. On average, a
modern vacuum booster generates 810 PSI of pressure
[12]

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Figure 8 Vacuum Booster in Use [11]

. This pressure generated inside the vacuum booster is

then pressed against a diaphragm. The diaphragm is between 8-12 in diameter. Once the force
that are generated by both the driver and the vacuum booster are combined, that force is then
transferred to the master cylinder where the barking fluid is then acted upon. Here, the pressure
acting on the brake fluid is between 800-2000 PSI [8]. The 800 PSI is when the driver is under
very light braking, while 2000 PSI is an emergency braking situation.
Stabilization
Making good contact with the ground is critical for safety reasons. The idea of
stabilization here comes from how recreational campers are stabilized with jacks. On these
stabilization systems, there are usually 4 jacks or stabilizers
depending on the size of the vehicle or trailer. The idea for
this system came from patent US20120091411 [13]. This
technolgy allows the camper to have support rather then just
the tires on the gound. In a jack system such as the design
being proposed it is important to keep the system stable.

Figure 9. Recreational
Camper Stabilization [13]

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2. Design Solution
The IAJ system was developed by applying principles and knowledge such as Pascals
Law, mechanical advantage, fluid mechanics, and mechanics. This design solution focuses on
reducing the time spent outside of ones car during roadside maintenance as well as removing the
possibility of wrong placement of a jack.
The IAJ incorporates 4 compact
bottle jack assemblies which are powered
by the brake line system. Each of the
bottle jack assemblies are composed of a 3
section bottle jack and a bracket system
which is mounted to the frame of the car. One assembly

Figure 10. Jack Placement

is mounted behind each one of the tires shown in figure 10. The bracket assemblies utilize 3 CChannels which the bottle jacks can slide up and down on with consistence and support further
explained in section 4. Additionally, a threaded collar is used to lock the bottle jacks in place in
the up or down position. This ensures that the bottle jacks cannot extend when unintended
causing a dangerous situation. Stability was a top priority during the design of the system. For
this reason, the system is designed to raise both of the front jacks or both of the rear jacks
simultaneously. This will ensure that there are always 4 points of contact with the ground,
ensuring safe raising and lowering of the automobile (two jacks and two tires). To further
stabilize the car, the bottom of the jacks are equipped with a stabilizing foot which is free to
rotate due to a pin connection. This will provide better stability on slightly uneven surfaces such
as an incline. The system is powered by the brake line pressure produced by pressing the brake
pedal. In order to divert the brake fluid to the jacks without affecting normal braking operation, 2

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isolation valves are connected to the brake lines near each wheel shown in figure 11. One valve
will govern flow from the brake line to
the brake caliper and the other isolation
valve will govern flow from the brake
line to the bottle jack. Both of these
valves will be operated by a single
switch. When the switch is activated,
the first isolation valve will cut off flow
to the caliper, and the second gate valve
will open up flow to the bottle jack
simultaneously.
1: Brake system including master
cylinder, vacuum booster, and brake
pedal.
2: Battery
3: Jack Valve Box
4: Control Box
5: Parking Brake Control
6: Jack Assembly
7: Tire

Figure 11 System Schematic

8: Electronic Isolation Valve

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Table 1: Bill of Materials

Part
Part Name

Quantity

Material

Brake Line

(50 feet)

Multi-layer Braided Hose

Control Module

Electronic Isolation Valve

Stainless Steel

Modified Bottle Jack

ASTM A36

C-Channel

12

(Car Frame Material)

Locking Collar

Aluminum 2024

Valve Box

Aluminum 2011

Check Valve

Type 316 Stainless Steel

Release/Screw Valve

Type 303 Stainless Steel

Number

The bill of material shows the quantity of each individual component needed and the material
used. Section 4 further discusses each component and technical drawings are provided in the
appendix.

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3. Design Analysis
The first thing we took into consideration is if pressure that generated in by brake system
is sufficient to lift the car. Through calculations that are shown later in this section, there is
sufficient pressure to make a system like this operate. The next step was to design the
components and make sure all components can with stand the required pressure and force of
lifting a car. We discovered that the average brake line pressure which was found to be between
800 PSI and 2000 PSI [14]. At 800 PSI is a normal braking situations, while 2000 PSI is in a worst
case scenario situation, like avoiding an accident. To avoid having an operating pressure too high
compared to the brake line pressure threshold, a target pressure of 1500 PSI was set.

Figure 12 and 13: Weight distribution in common cars [14] [15]

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In figure 14 and 15, the common weight distributions in modern cars. Typically, the
distribution varies and may not be exactly 50:50, but with safety and handling is becoming more
and more instituted by manufacturers, 50:50 will soon be the new common. It shows that the
weight is fairly evenly distributed, so for analytical purposes we assumed the car had 50:50
weight distribution from front to back. This means that 50% of the cars weight is at the back,
while the other 50% is to the front. Also, we assumed the car had 50:50 distribution to the left
and right. The weight of the car was assumed 3500 lbs which is currently the average weight of
most cars. In a force analysis of one corner of a car, which that jack will needs to lift 875 lbs.
Assumed sized are as follows:
-

Brake Line dia. = d1 = 1/4

Jack Piston dia. = d2 = 1

Using Pascals Law to see if this was feasibly, we obtained

1 2
(875)
(
1 2
2 1
4) = 54.7
1 = 2
=
1 =
=
1 2
2
12

1 = 1/1 =

54.7
1 2
((4) )
4

= 1114.1

Where
F1 = force in brake fluid
F2 = force of car weight
A1 = area of brake line
A2 = area of jack piston diameter

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Since both cross-sectional areas both include /4, only the diameters are used

15

The pressure required from the brake lines roughly 1115 PSI which is right is the range
we need so this system can operate. Working the problem with a larger diameter brake line will
reduce the required force. Next, the pressure of the brake system must be evaluated. Figure 14 on
the next page shows how the calculation was performed.

Figure 14 Brake Pressure Analysis

To analyze the jack to make sure there is no

failure due to lifting a car, we used ANSYS 16.2 to
perform a static structural analysis. Figure 15 below
shows the boundary conditions that were applied to
perform the analysis. It is important to note that due
to symmetry of the model, half the model was
analyzed. For clarity, simplicity, and basic ANSYS
operation techniques, only half is used. A is a
frictionless support on the face of symmetry. B is
a pressure of 1150 PSI (generated by the driver and
the braking system) applied to all interior faces in
Figure 15 Static Structure

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the jack. This pressure is transferred from the brake

fluid and exerted outwards. 1150 was used instead of
1115 to allow for some extra weight in the car. C is
an upward force of 1000 lb. This represents 25% on a
4000lb. car being lifted. We used the force of 1000 lb.
instead of 875 lb. previously stated to ensure there was
some allowance of extra weight also. Lastly, D is a
fixed support. This represents the locking collar.
During operation, the threads will be secured to the
collar, and therefore not move. Data we obtained from
the analysis is shown by the following figures. The
Figure 16 Jack Safety Factor

collar was not analyzed due to the results generated on the

threads of the housing. There is essentially negligible stress at this location.

For results, the factor of safety and von-Mises stress are shown. In figure 16, the factor of
safety is shown for the whole jack while the forces are applied. The minimum factor of safety is
2.3196 which is located on the pad (fig. 17). Figures 16-21 show the factor of safety for all
individual parts related to the jack itself.

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Figure 17 Foot Structure

Figure 19 Lower Extension Safety Factor

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Figure 18 Pin Safety Factor

Figure 20 Upper Extension Safety Factor

18

Figure 21 Housing Safety Factor

Along with the factor of safety of each

component, the von-Mises stress for the
individual parts is shown below in figures 2227. The max stress in the system is 15632 PSI,
located in the pad (fig. 23) where the lowest
factor of safety is located. The minimum
pressure is located in the housing (fig. 26),
which is 7.69*10-3 PSI.

Figure 22 Overall Jack Stress

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Figure 23 Foot Stress

Figure 24 Lower Extension Stress

Figure 25 Upper Extension Stress

Figure 26 Housing Stress

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Figure 27 Pin Stress

From analyzing the ANSYS simulation, its clear that the system will operate without
failure, having a minimum factor of safety of 2.3. The weakest link of the system is the pad,
where the stress is the highest at the point of the pin connects the pad and the lower extension.

Max. Factor of
Safety
Min. Factor of
Safety
Max von-Mises
Stress (PSI)
Min. von-Mises
Stress (PSI)

Housing

Upper
Extension

Lower
Extension

Pad

Pin

15

15

15

15

15

4.7791

4.5289

2.8715

2.3196

6.5174

7587.1

8006.2

12627

15632

5563.5

7.69*10-3

344.9

401.05

1.8997

67.4

Table 2: Values of Factor of Safety and von-Mises Stress

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The last criteria that was evaluated to make the system feasible is to analyze how much extra
brake fluid would be needed to fully fill the jack. The table below shows the volumes of the housing and
both extensions.
Housing

9.32 in3

Upper Extension

5.37 in3

Lower Extension

1.93 in3

Total Volume of Jack

16.6 in3

Table 3: Volume of Jack

The total volume of one jack assembly is 16.6 in3. Converting this value into a more
visual unit, this converts to 9.21 fl. Oz. This is roughly of a typical 12 oz. soda can of fluid per
jack. Since there will be 2 jacks operating at the same time, this valve doubles to 18.4 fl. Oz. To
take into account the amount in the brake lines from the jack to the brake line connection, and to
make sure theres extra in the system, the extra amount needed will be 20-21 fl Oz. A car will
typically contain 34-51 fl Oz. (1-1.5 Liters) of brake fluid from the factory. In total, the system
will need to carry 55-75 fl Oz. of fluid, which is +/- .5 gallons.

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4. Design Components
The design is composed of a number of components. The brake system will remain the
same with only a larger reservoir for additional brake fluid. This was a requirement when
beginning the design process in order to minimize cost and effecting the design of the rest of the
vehicle. The remaining components integrated into the system are brake lines, the system
controller and circuity for the isolation valves, and the jack with its own set of components
further elaborated on in section 4.4.
4.1 Brake lines
The brake lines are needed to transfer the fluid from the reservoir to the brakes and when
the jacks are engaged, to the jacks. The lines recommended to the manufacturer will be steel
braided lines composed of layers of polymers and stainless steel as shown in figure 28. The steel
is necessary because this material will be stronger and not deform when the high pressure is
applied, unlike rubber or plastic.
When a new car hits the road, it is
suggested that the operator does not
apply high pressure to the brake for
some time. This is to allow the brake
Figure 28 Brake Line Cut-away [17]

lines to break in and not malfunction

prematurely. The lines recommend will outperform the more commonly used lines allowing the
increased pressure to not be a problem. Since there is a significant quantity of fluid being
pumped inch lines will be used throughout the system. This is slightly larger the standard
3/16 but there are already fittings and lines made in for between some off the major brake

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components in previous cars. This will keep manufacturing costs lower as there are already lines
and connections from off the shelf that have been developed and tested.
4.2 System Controller and Circuitry
Once the desired jacks are released with the locking collar and contacting the ground, the
side of the car needed to be lifted will be chosen from the control panel. The switch on this panel
will control valves in a certain way to allow the working fluid be diverted to the correct jacks.
This system will operate as a simple circuit. When the switch is flipped one way, one circuit is
opened while the other is closed. When the switch positions, the circuit path is switched. On the
user interface, there will be a light that indicated what mode the system is in (jacks operating or
off). The electric power required to operate the actuators for the valves will be taped off the ABS
system and the controller box will have a new power line ran from the fuse box. Since the focus
is on the jack and the design of the jack, there is no emphasis of the electronic system; basic
wiring techniques and methods will be sufficient.

Figure 29 System Controller Schematic

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4.3 Electronic Isolation Valve

Closing the lines going to the brake calipers will have to
be done by a gate or knife valve. This line needs to fully
open to allow for minimal resistance and interference for the
brake fluid. Along with this reason, these valves will also
completely close off a section of line, allowing the brake
fluid to work directly for the jacks when needed. Typical
valves that are currently manufactured can withstand
pressure upwards of 10,000 PSI, well above the possible
working pressure of the braking system. The valve in figure

Figure 30 Electronic Isolation

Valve [18]

29 is a inch normally closed stainless steel solenoid valve

found on McMaster-Carr [18].
4.4 Jack Design
The jack proposed for the system needed to
be designed rather than utilized from an already
developed product. This is because most jacks are
placed on the ground and used to raise the car or
other object up. However, with this system, the jack
will need to extend downward from the car to the
ground, then raise the car. To do this the jack needs
to be reversed. The jack design that was modified is
the bottle jack due to its capability of working in a
hydraulic system off the brakes. The bottle jack

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Figure 31 Extended Jack and Compressed Jack

25

section with the largest diameter needed to be on the top rather the bottom. This is because rather
having a base on the ground it has to have a bracket holding it to the vehicle. The bracket
designed will be comprised of C-channel sliders and a collar, which will be further described in
section 4.4.1. The body of the wall be comprised of 3 sections made of ASTM A36 structural
steel that will be able to telescope. Then the valve system, described in section 4.4.2 will be used
to allow the pressure to raise the vehicle without allowing the pressure to dissipate once the
driving force is removed. It will also allow the pressure in the system to be released when the
jack needs to go back into storage underneath the vehicle.
4.4.1 Bracket System
The bracket system will be composed of a Cchannel slider, a plate/section of the frame, and a locking
collar. The sliding mechanism will be used to allow the
jack to make contact with the ground before utilizing the

Figure 32 Locking Collar

hydraulic system. This allows for a smaller jack making it much

easier to store in a compact vehicle. The plate is
part of the vehicles frame that limits the jack
from sliding out of the C-channel slider.
Depending on the vehicle this could be an
additional plate or just a hole drilled into the
frame. The shape of the jack is what stops it
from continuing past the plate. The collar is the
part that holds the jack in place safety after sliding or when the
Figure 33 C Channel

vehicle is operational. In order to reduce weight and help with

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corrosion on an exterior part, it will be made from Aluminum 2024. It is attached to the plate and
is able to rotate to thread to the outer body of the jack. This system was a key design in making
this system feasible to remain in the vehicle as it is in
motion.
4.4.2 Jack Valve Box
Since the brake fluid pressure will not be
constantly applied, two valves will be used to control
flow. This system required a flow controlling device to
be in the system without an external activation
method.
Ball valves are commonly used in
reciprocating pump and reciprocating systems as they
can be operated by the fluid itself. The ball valve used
in this system will have a spring, similar to what is used in current

Figure 34 Valve Jack Box

bottle jacks, will placed along the lines that will carry
the brake fluid. The spring is the system will allow a
ball valve to allow one direction of the flow of a fluid.
When the fluid is flowing to the jack, the valve will be
forced open due to the pressure of the fluid being
pumped through. When no fluid is being forced
through the system, the ball valve will be fully closed
due to the force of the fluid inside the jack pushing
against the bearing as well as the spring. This will allow the ball

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Figure 35 Check Valve [19]

27

valve to be fully seated and not allow any fluid to flow back
from the jack and into the system. The valve used for this task
shown in figure 35 is a type 316 stainless steel preventing
corrosion but having high strength to allow the high
pressure[19].
To make sure the flow is fully reversible, another valve
was needed, as well as a was to release the fluid. If there was
another ball valve that operated in the opposite direction, there
would be no fluid retension inside the system. Since bottle

Figure 36 Release/Screw Valve [20]

jacks operate with a hand lever that does not return to center unlike the brake system, methods to
make sure the fluid stayed in the jack, as well as would be released when to be developed. A
release valve is needed to
lower the car back to the
ground and allow the jack to
be stored in the frame rails
and must be easily operated.
A screw valve, figure 36,
which is made from type 303
stainless steel, allowed the
pressure to be slowly released
to lower the vehicle [20]. Each
jack will have a screw valve
attached valve box. After the
Figure 37 Flow Schematic

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system is finished being used to perform any tasks the two jacks being used must be released of
pressure. This is to ensure the car doesnt slam to the ground when the pressure is released.
However, when it is time to retract the jack back into the frame, the operator must manually open
the valve. Fig. 37 is the flow schematic of how the brake fluid will flow through the valves

4.4.3 Stabilizing Foot

A pin is used to allow the foot to pivot
from the jack. With many jacks they are
designed to be in a shop type setting where
there is a perfectly level slab of concrete. With
this design there may be a slight incline or

Figure 38 Stabilizing Foot

decline in the road the jack is being used on, so for safety
reasons, the base must articulate. When using the system it is recommended to be on perfectly
level ground, but for practical purposes this system will be implemented to allow the safest
conditions in an unideal environment.
4.4.4 Seals
Seals used in conventional jack work well for
hydraulic fluid. In this system this would not work due
to the high corrosiveness of brake fluid. The most
suitable from a short list of suitable materials for brake fluid is

Figure 39 U-cup Seal

Virgin PTFE also known as Teflon [21] . The most common failure in Jacks is due to the seal [22].
To minimize this u-cup seals were used rather than O-ring. This significant price increase is
necessary to prolong the life of the high pressure system significantly.

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5. Conclusion
The two main goals of the IAJ were to reduce the time spent outside of ones' vehicle
during roadside maintenance, and to make jacking up a car a safer and easier task for
everyone. By utilizing preexisting technologies such as brake systems, hydraulic bottle jacks,
c-channels, check valves, and release valves the Integrated Automobile Jack System was
designed. Theoretically the IAJ could accomplish both goals successfully.
The feasibility of the system had to be looked into. The first step was determining the
average pressure that a brake system in a car generates. This pressure was found to be 800
Psi during normal operating conditions and up to 2000 Psi during intense braking situations.
Next, Pascal's Law was used to find the pressure needed to lift 25% of an average car using a
bottle jack. The pressure required to lift the 875 lbs turned out to be 1115 Psi. This pressure
is easily achievable using your average brake system.
Physical design limitations were governed by the compact layout of the modern
automobile, causing the IAJ to be developed using a minimalistic design approach. For this
reason, all components were designed to take up as little space as possible. Parts of the IAJ
were drawn on Solidworks enabling ANSYS simulation to be performed. The bracket
system, jack valve box, and stabilizing foot were all custom designed. The bottle jack
previously existed but was modified to incorporate 3 c-channel guides on the base as well as
a pin hole on the end of the smallest segment for the foot structure.
An ANSYS simulation was performed to ensure that the final design would prevail
during use. The first simulation resulted in a failure in the foot structure. To correct this
shortcoming, the foot structure design was strengthened by thickening the point of contact

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with the base. After this improvement, a second ANSYS simulation went successfully. The
minimum factor of safety was found to be 2.3196 and is located on the foot structure. The
maximum stress was found to be 15632 Psi and occurs in the same location as the minimum
factor of safety. With a factor of safety of 2.3, the design is certainly structurally safe and
will be able to hold up a car safety.

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6. References
[1] "Causes of Breakdown." Top Ten Causes of Breakdown. N.p., n.d. Web. 17 Apr. 2016.
from https://www.theaa.com/breakdown-cover/top-ten-breakdown-causes.html
[2] "Changing a Flat Tire on the Road." Examiner.com. N.p., n.d. Web. 17 Apr. 2016. from
http://www.examiner.com/article/changing-a-flat-tire-on-the-road
[3] Muchnik, J. (2007, December 7). History of Hydraulic Jacks. Retrieved February 5, 2015,
from http://ezinearticles.com/?History-of-Hydraulic-Jacks&id=886634
[4] Cengel, Y., & Boles, M. (2015). Thermodynamics. New York: McGraw-Hill Education.
[5] Millar, D. (1975). Electro-hydraulic jack.
Patent US3918683 A
[6] "Pascal's Law | Premed HQ." Premed HQ. N.p., n.d. Web. 15 Apr. 2016. from
https://www.premedhq.com/pascals-law
[7] Mstworkbooks.co.za,. (2015). Gr9 Technology. Retrieved 25 February 2015, from
http://www.mstworkbooks.co.za/technology/gr9/gr9-technology-06.html
[8] Patrascu, D. (2009, May 20). Braking Systems History. Retrieved February 5, 2015, from
http://www.autoevolution.com/news/braking-systems-history-6933.html
[9] How a car works,. (2015). How the braking system works. Retrieved 3 February 2015, from
http://www.howacarworks.com/basics/how-the-braking-system-works

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[10] Brake System Pictures--IBSTR. (2016). Ibsrt.com. Retrieved 25 April 2016, from
http://www.ibsrt.com/imglist/Brake-System-id-260-p-1.html
[11] AGCO Automotive Repair Service - Baton Rouge, LA - Detailed Auto Topics Vacuum
Brake Boosters. (2016). Agcoauto.com. Retrieved 25 April 2016, from
http://www.agcoauto.com/content/news/p2_articleid/129
[12] BRAKE MATH: CALCULATING THE FORCE NEEDED TO STOP A CAR. (2010). Brake
& Front End. Retrieved 8 April 2016, from http://www.brakeandfrontend.com/brake-mathcalculating-the-force-needed-to-stop-a-car/
[13] BLUEROCK TECHNOLOGIES, INC.,. 'SELF-RETRACTING HYDRAULIC JACK
ASSEMBLY'. 2011: n. pag. Print.
Patent US20120091411 A-1
[14] Brake System and Upgrade Selection. (2016). Stoptech.com. Retrieved 3 April 2016, from
http://stoptech.com/technical-support/technical-white-papers/brake-system-and-upgradeselection
[15] Understanding Corner Weights. (2016). Sccawiregrass.org. Retrieved 3 April 2016, from
http://www.sccawiregrass.org/weight.html
[16] The Science of Your Car | Americas Best Automotive Alpharetta GA.
(2016).Americasbestautomotive.com. Retrieved 3 April 2016, from
http://americasbestautomotive.com/the-science-of-your-car/
[17] Performance Brake Blog - How Stainless Steel Brake Lines Help Your Braking, Versus
Plain Rubber | Cquence.net. (2016). Cquence.net. Retrieved 3 April 2016, from
http://www.cquence.net/blog/how-stainless-steel-brake-lines-improve-braking-performance/
[18] McMaster-Carr. (2016). Mcmaster.com. Retrieved 15 March 2016, from
http://www.mcmaster.com/#4711k511/=1271tv3
[19] McMaster-Carr. (2016). Mcmaster.com. Retrieved 15 March 2016, from
http://www.mcmaster.com/#7838k54/=12950lr
[20] McMaster-Carr. (2016). Mcmaster.com. Retrieved 15 March 2016, from
http://www.mcmaster.com/#7824k33/=11soqck

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[21] Efunda.com,. (2015). eFunda: O-Ring Materials Compatibile with Chemical Brake Fluid.
Retrieved 1 March 2015, from
http://www.efunda.com/designStandards/oring/oring_chemical.cfm?SM=none&SC=Brake
%20Fluid
[22] O'Brien, L. (2016). Common Reasons for Jack Failure - e2bcal Blog. e2bcal Blog.
Retrieved 18 March 2016, from http://blog.e2bcal.com/2016/03/common-reasons-for-jackfailure/

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Apendix

Integrated Automobile Jack Users Manual

Part I. Raising the Car

1. Turn the car on and confirm the transmission is in Park. The safety mechanism will not
allow the system to function if the car is not in Park.
2. Fully depress the brake pedal and toggle the switch for the front or rear jacks, depending
on which pair you need to engage.
3. Exit the vehicle and release either the 2 front or 2 rear jacks by loosening the locking
collar, lowering the jack, and then tightening the collar.
4. Return to the vehicle and begin cyclically pressing the brake pedal with slow and
complete strokes until there is no more contact between the tire and the ground.

Part II. Lowering the Car

1. Release the pressure from the system via the screw valve; be sure the area underneath the
car and tires is clear from obstructions or body parts.
2. Unscrew the Locking collar, raise the housing of the jack to its storage position and
tighten the collar once more.
3. Lift the remaining jack extensions back into the jack housing and close the screw valve.

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