Chapter One 1. History of Bishoftu Automotive Industry: Mekelle University

Mekelle University 2013
CHAPTER ONE
1. History of Bishoftu Automotive Industry

BAI is found in Debrezeit, special name of Arbashe. It’s about 47Km from Addis Ababa. It is
one of the Engineering Military complexes in Defence Industry Sector.
Project 40720 is first name of BAI. Project 40720 was originally design to render maintenance
service for tanks, armoured vehicles, military wheeled vehicles, artillery weapons, optical device,
small arms and communications and control equipment’s.
Implementation of the project began in Feb.1984 and was interrupted in May 1991 following the
fall of the Derge regime. A substantial magnitude of construction works of the complex has been
excited and some machineries and equipment installation has been carried out prior to the
interruption of activities.
1.1. Objectives Of Project 40720

 To overhaul and medium repair of armoured and automotive materials.
 To overhaul medium and running repair of engineering materials.
 To overhaul and running repair of artillery materials, optic devices, tank guns,
stabilizers, panel equipment’s and small arms.
 To overhaul of communication means.
 To maintain radar stations, anti-air craft guns.
1.2. Organization Set Up Of Project 40720
The project is managed by a General Manager accountable to the Ministry of National Defence
and/or to the bored management and under it, there exist three line department and one staff unit
namely:-
1) Operation and Engineering Department

2) Procurement and supplier management department
3) Administration and finance management department
4) Quality control and inspection service
The operation and Engineering department further manages four line work units and two support
units under it:-
i. Armoured materials overhaul work shop

ii. Light trucks and automotive overhaul work shop
iii. Engine overhaul and mechanical work shop
iv. Artillery material overhaul work shop
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v. Design and product development service
vi. Maintenance and utility service
At present, the industry by making good relationship with foreign countries especially with
Chinese automotive companies it changes most of the products including its name called BAI. It
also changes almost all workshops. Therefore the operation and Engineering department now
manages the following workshops and support units:-
a) Tank production factory

 In this factory there are three main products,see the picture
Fig.1. Tank Fig.2. (BRDM)
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Fig.3. Zilla (adma betagn)
b) Engine and power train production factory

 Main product of this factory is V12 tank engine
c) Construction machinery production factory
-This factory is now moving out to Debre Berhan city(1-10-2005),but some of
the products are
 Dozer
 Excavator
 Grader
 Loader
 Cranes etc.
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Fig.2.
d) Vehicle system production factory
 Main products this factory is motorcycle, but it is not going to be the only
one the company is dealing with some china factories to start production
of Bajaj and Bicycle.
Fig.3.
e) Heavy Duty truck production factory
 Main products of this factory are dump trucks (FAW, Howo-Sinotruck,
KAMAZ, Beiben etc),cargo trucks, military trucks
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Fig.4
f) Body and frame production factory
-Main product of this factory is production of body for the
Assembled dump, cargo trucks.
g) Heavy duty testing shop
-this shop is fully computerized; each testing stage is result is displayed in
the computer room. This shop gives test only for 2WD trucks. There are
five stages in the shop
Stage1.Axel weight testing, gross weight of the truck,
break efficiency for each tyre
Stage2.cars millage (measures KPh, at maximum speed of
the truck) .
Stage3.fuel consumption when it is ideal,20KPh etc, also
Smoke testing machine.
Stage4.tests wheel alignment, free play ,hand break, foot
Break.
Stage5.side slip testing, light adjustment, horn
(Bus testing machine is under construction)
H )Design and product development service
I) Bus production factory
This factory one of the largest factory in the company,it produces city busses,
public transport busses.
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Fig.5
J).Automobile production factory
-Main products of this factory are single cabin, double carbine, and
SUV cars.
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Fig.6
1.3. Main Products & Customers

Main Products
 Production of city Busses, Public transport busses

 Production of construction machineries such as Dozers, Excavators, Rollers, Graders and
Dumper Truck
 Production of Pick up automobile
 Production of Heavy duty Trucks
 Production of different automobile and heavy trucks body
 Maintenance of engines and power trains
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 Production of motorcycle
Main Costumers
 Different government and private organizations.
 Different Construction Company.
 Anbesa City Bus Company.
 Also Ministry of Defence is the main user of this industry.
 International organizations like UN.
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CHAPTER TWO
2. Overall Internship Experience
Within the four month of internship time we work in different workshops of BAI. Such as
engine and power train production factory, heavy duty production factories , body and frame
production factory, vehicles system production factory, bus production factory and automobile
production factory.
2.1. Engine & Power Train Production Factory
Engine and power train production factory mainly designed for:-
 Overhaul maintenance and test of engine used in armoured material vehicles

and testing of power supply units. i.e. Oral and tank engines and power supply
units.
 Also for manufacturing of easily produced parts.
But in addition to this it also gives a maintenance service for company’s vehicles and sometimes
private automobiles.
This factory has two shops. The first one is engine repair shop. This shop is used for overall
maintenance of engines only. And the second one is used for overall maintenance of power
supply units such as Differential, Gear Box, and Transfer Case. Now this shop also divided into
two and half part of the shop is used for production of city bus vehicles.
2.1.1. Process Flow of Engine Repair Shop
In engine repair shop there are many tasks could be done. These tasks have their own steps.
These are disassembling, washing, inspection, maintenance and assembly.
Disassembling
In this stages engines disassembled into components and parts. All parts of engines will be
disassembled and small parts such as bolts, nuts, etc. put in a dish. Similarly crank shaft, piston
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head, and other heavy parts will be hosted by the crane and sit on washing machine. There is no
different method or unique machine to disassembling process simply uses a number of wrenches.
Washing
After disassembling, parts and components of engines will be washed. This washing machine
initially used steam to wash. But now it is not working and instead of steam it uses hot water.
Inspection
After parts have been washed, the next stage will be inspection. The first part of the inspection
process will be the visual inspection. Through this process we will recognize if there are any
problems like, crack and breakage on the engine housing and the other parts.
The parts that are inspected usually in the inspection room are the engine housing, the crank
shaft, the cam shaft, journal/shell bearing and the valves.
For the inspection of these parts we will use instrument like the micrometer, Varner caliper, and
magnetic stand with a dial, dial gage and bore gage.
During the inspection of the crank shaft housing first we will tighten the shafts of the case to the
right torque from the manual and then we turn it again to the right degree which we get from the
manual. Then we can measure the diameter of the hole either with bearing or without, using the
bore gage. We can measure the diameter of the cam shaft housing with the same way if it in case
and not overhead.
On the cam shaft and crank shaft there are two things that we must do; the first is we measure the
diameter of the journals and mid portion by using micrometer. The second inspection is
determining the bend of the rod. We do this by using magnetic stand.
Then after taking these tests we take the result and compare them with the allowable values of
manual. If the value is within range we can pass it as usable and if it is out of range it will be
either maintained or replaced.
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Inspection of the valve will be accomplished by checking whether the valve gained is usable or
not and if the valve head fits with the engine head opening.
Maintenance
After the parts of engine (mainly the crank shaft, camshaft and engine cylinder) have been
inspected, if there is a faulty part it will have to be maintained to suitable value.
There are different maintaining methods that will be used for different parts. For the cam shaft
parts will be either ground to suitable value, if it has been greater than the set value or it will be
filled by welding and ground to a suitable value, if it has been lower than the set value.
For the crank shaft also, the same procedure that has been used for the cam shaft will be used.
The grounding procedure will be done on a special type of lathe machine that has a suitable
mechanism for this purpose.
The crank shaft holder is also maintained by using a boring machine specially set for this
purpose. As for the cylinder lining, a new lining will be inserted into the old one and it will be
bored into a suitable value with a special boring machine.
Assembly
Unlike disassembling work group, the assembly section follows a set of procedures as set by
manufacturer on the manual.
Special tools may be used in assembly specific to the part that will be assembled. Most of these
tools are custom made to lessen the difficulty and reduce the time that the assembly process
causes.
But even with the special tools the assembly process is tiresome and time consuming. The main
cause to this problem is the engine time setting process. On the tank engine the engine time
seating process may take up to one or more days.
2.1.2. Process Flow Of Power Supply Units Repair Shop
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Similar to engine repair shop, this shop also have different flow process. Just like engine repair
shop, starting from disassembling process up to assembly. The only difference between the two
shops is the repair parts. I.e. in this shop instead of engines the shop repairs power supply units
such as differential, gear box and transfer case.
2.1.3. Work Task In This Shop
Within a month of working time in this shop we have done many tasks. But the main task is
studying the overall flow process and problems that affect the flow of the shop. And also I
participate in practical works. For example I work with the inspection group and me measure and
compare (cam shafts, crank shafts, piston head …) with the manual. In addition to this we also
participate in disassembling and assembling process.
2.1.4. Challenges
There are many challenges that we have been facing during performing our tasks.
The first one is misunderstanding. This is the first problem that we faced in this shop. The
workers think us a general mechanic student and they assigned us a hard working area. That is
hoisting very heavy parts, disassembled parts, etc. Generally the first two and three weeks are
very difficult to us.
The other problems that we observe are highly affect the overall flow process of the shop. These
are:-
i. Layout of the shop

ii. Maintained automobile parking place
iii. Spar part supply
iv. Useless machines
The above main problems affect the flow process of the shop by losing time, crowded of
working place, decreasing life time of the crane, safety of the workers, etc.
2.2. Construction Machinery Production Factory
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In construction machinery production factory mainly designed for production of all types of
construction machineries, such as Dozers, Excavators, Graders, Loaders, and Rollers. In addition
to this the shop also gives a maintenance service for all construction machineries.
Each type of machineries can be produced in different shop. During the time we work in this
factory all those shops are stopped producing dozers, excavators, graders, loaders, and rollers.
Because they are moving out to Debre -Brhan city to open their new branch.
2.3. Body & Frame Production Factory
This factory mainly designed for production of different trucks body and frames. It has three
shops:-
a) New Production Shop
In this shop new body and frame of different trucks will be produced. For example this shop
produces an ambulance which is used for transport many wounded soldiers at a time. This
ambulance has more than eight beds.
Similarly this shop also produces city buses. They finished one sample and over 50 frames.
In addition to this, now a time this shop also produces different types of body. Such as the body
of heavy trucks that are assembled in BAI, Deeper body, Beiben, Oval cabin, Damper, etc.
b) Overhaul Shop
Body and frame of trucks that can be damaged by accident can be overhaul or maintained in this
shop. Simply in this shop gives a maintenance service for crashed body and frame of all types of
vehicles not a new design.
c) Integration Shop
This shop mainly designed for finishing process of body and frame of the vehicles. Such as
painting, assembly of chairs, assembly of mirrors, different types of lighting system, light and
different control systems etc. therefore body of the truck after finishing from the new production
and overhaul shop directly go to integration shop for the final stage.
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2.3.1. Overall Flow Process Of Producing The Body Of Heavy Trucks
we left a few days in this shop and we saw how to produce the body of heavy duty trucks that are
produced in Heavy Trucks Production Factory. First the design room takes the overall drawing
of the chassis of the truck. Then by using this drawing they design the five part of the body that
feat the given dimension of the chassis.
This design is done by computer by using CATIA software. After this the drawing is print out
and moves to work shop. Next the floor part, the right side, the left side, the front and the rare
side of the body is produced respectively. Finally all four parts welded on the floor part of the
body and we get the final product.
Those processes pass different manufacturing methods. Such as bending and welding. Finally the
body go to the integration shop and the painting process is applied.
2.3.2. Work Task In This Shop
In this shop our task is studying the overall flow process and problems that affect the flow
process of the shop. Similarly we participate in design room during body design.
2.3.3. Challenges
In this shop we faced many problems. Initially the shop is very small and it is full when two
trucks are getting in and it is crowded. The shop is not well organized. This means there is idel
time of workers.
2.4. Vehicle Production Factory
This factory mainly designed for production of city buses (i.e. buses now the time we are looking
in Addis Ababa city called Bishoftu Bus). There are three shops:-
i. Body & Frame Shop
ii. Painting Shop
iii. Finishing Shop
2.4.1. Overall Flow Process Of Production Of Buses

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In our intern ship time we work a few days in this shop and we saw the overall flow process of
production. The flow process starts in body and frame shop.
i. Body & Frame Shop
Almost all parts of the bus are assembled in this shop. This shop also divided into two rows. The
first step is starts in the first row which is welding different parts of the chassis. Then assemble
the axle with chassis and assemble all the tyres. The next stage is assembly of the main parts of
the bus i.e. engines, gear box, different cables, propeller shafts, and steering system. After this it
moves into the second rows and first the frame of the bus is welded on the chassis. Then the
sheet metal is welded into the frame. Finally we get the final body of the bus.
ii. Painting Shop
The finished body of the bus then go to the painting shop. This shop also has two rooms. In the
first room the first step is removing the rough surface of the body that caused by welding of sheet
metals with welding. If the body is quit smooth the next step is painting. Then the bus inters the
second room and the paint is drying within a few minutes. This room mainly design for drying of
paints. It uses a lot of light for drying paint.
iii. Finishing Shop
The final stage is completed in this shop. All the finishing process is done by this shop. The first
step is assembly of the door. Then AC system, speakers, light and the roof is assembled. Next
chairs of the bus are assembled. After this all types of mirrors take their position. Finally
different types of electrical systems assembled such as light, radio, gauges, etc.
2.5. Vehicles System Production Factory
The vehicles system production factory is concerned with maintaining parts of armoured
and construction vehicles that are concerned with controlling the delivery of the needed work.
They might do this either by controlling the fuel that is desired to the engine of construction
machinery or by controlling the movement of the turret of tank machine.
2.5.1. Flow Process Of The Shop
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The vehicles system production factory is organized by two main groups. These are:-
(i) Mechanical work group

1. Fuel systems
2. Radiator and Exhaust manifold
3. Steering system
(ii) Electrical work group
1. Hydraulic Booster
2. Stabilizer
3. DC motors
4. Wiring
1. Fuel Systems
In the fuel system work group the main parts that are mainly overhauled are oil pump and
injection pump.
The work flow in overhauling oil pump is, first it must be disassembled and each parts will be
washed so that there will be no impurity that will interfere with the process of inspection.
The oil pump uses gear pump and that will sustain heavy damage of corrosion are the gear
housing since there will be repeated interaction between the gears and the housing. Since the
pump works by trapping the oil between the gear teeth; if the housing is corroded, oil will leak
resulting in drop in pressure.
Therefore in the inspection, we will try to determine the variation of the values of the diameter of
the gear housing from the set value in the manual. We will also measure the tooth dimension by
using the tooth gauge.
If the tooth is corroded, the only thing is performed in the factory is to replace the corroded tooth
by purchasing a new one. The housing can be maintained by using grinding or by filling with
weld and grinding.
Similar to the oil pump the work flow of the injection pump starts by disassembly and washing
the parts. In this work group both the in line and rotary injection pumps are overhauled.
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The parts of the injection pump that fails most of the time is the injection nozzle. This might
occur either by accumulation of impurity at the opening or the failure of magnetic property of the
injection rod. Due to these problems, there will be a variation of pressure from the set value from
the manual.
To determine if the nozzle is faulty or not, we measure the pressure by using the pressure gauge,
or we can see if the fuel comes out as a stream or spray by mounting the nozzle on an injection
nozzle testing stand and by adjusting the pressure. If the fuel comes out as a stream rather than
vaporized from the nozzle is faulty.
2. Radiator & Exhaust Manifold
In radiator work group different types of vehicles radiators overhauled. The first step in this
process is washing dirt and debris out of the fins of the radiator. This is done by adding the
radiator into a sink which is full of water and blowing air across it. In this process soap is also
included. Therefore when the air blows in the water bubbles will form and wash away the dirt
accumulated.
Then the radiator again dipped in to a sink which is full of water and the air blower through the
inside of the radiator in order to determine where the piping may have been ripped.
After the faulty place is determined, the next step will be to reconditioning it using the welding
method. Then to determine the welding is efficient, again we dip the radiator into the water and
see there is any bubbles come out.
In exhaust manifold work group different pipes that are used for transfer of fluid to and from the
engine of vehicles overhauled. Failure in the pipe will occur by pricing due to the different
abrasive impurities or due to heat.
Therefore the main types of maintenance that is done in this work group is either welding it to
fill the hole or replacing it by a new one if the pipe is to warm out to be reconditioned.
3. Steering System
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The shop is comprised of different test stands such as test stand for driver wheel mechanism and
hydraulic booster, service break, hand break and power steering mechanism.
Hydraulic steering mechanism consists of pressurised fluid (oil or air), valves, regulators,
cylinder and piston mechanism, relay switch and rack and pinion mechanism.
2.6. Measures That Overcome The Above All Challenges
As we can see in each shop all shops have their own problems or challenges. To avoid such
problems we made a report about each shop overall problems that affect the flow process of the
shop and we informed Design and product development service. In addition to this we design an
Automobile Lifting Machine(single scissor jack).
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CHAPTER THREE
3. INTRODUCTION
As a result of the out broke of industry revolution, engineers seek and of course go further
ahead, ways to do things easily and which save time and work force. So thus, in industry process
system. Products, items packages are mostly been segregated according to their quantity (size,
type weight) and quality (good/bad/). To do this quite a list of mechanical and electrical
methodology practiced. Among these:
1. After identifying guiding through a preferred path, usually used in considering its weight.
2. These are separated according to their size using plat form.
3. These are mostly used in lifting and lowering process where after interpreted individual
components of mechanical push, pulls etc.
In this project the scissor type hydraulic lift is the examples of which industry could enjoy and
used it as a segment of facilitate the lifting and lowering process.
To realize the above process segment a number of components like hydraulic actuator, hand
pump, one way valve, reservoir, piston rod, links etc
3.1. General objective

General objective of the project is to increase the production while maintaining quality &
Lowering cost, reducing time consumption taken by the job done without the jack; to make
the operation safer. And to produce a hydraulic single scissor jack.
3.2. Specific objective
Specific objective of the project is to solve the problem seen in the automobile production
factory of the company. we are going to solve this problem by designing a hydraulic single
scissor jack; that is going to be used for lifting the whole automobile during maintenance,
assembly etc conditions. We select this project because during operation in the automobile
production factory they use old technology or system of maintaining & assembling process;
which is by digging the floor and making a specific hole for the operator (worker).
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The disadvantage of this old system is

 Lack of light
 Operator can’t work freely which means limited working space.
 Consume time since only one or two operators work on the space
 Decrease speed of production, since there is only one digged part
 Fixed system which means the hole is not movable that increases the risk of danger
when the operator is short.
 Creates bad working condition which means it increase the working temperature.
To solve this problem we are going to design the hydraulic single scissor jack. In
addition to the maintenance system, this scissor jack is used for washing the
automobiles
After the end of this project the company can get the advantage around the work shop or station
of the pickups like.
- Good working environment

- Saving time during operation (production & maintenance).
- We can do the operation system at any place since the jack is movable.
- Operator can work freely because they have more free space.
- Increase the production rate
3.3. Scope of the project
The scope of this project is to design and prepare manufacturing process plan and fabrication
of scissor type hydraulic car lifter. Methodologies that are used in the project are manual,
library search, industrial visit and some websites.
3.4. problem definition
Since the company is using an old technology which means there is lack of a hydraulically
operated scissor car lifter, and this makes us motivated to design & manufacture the device.
Instead of buying a new lift device; we are here to design the hydraulic car lifter in order to
familiarize ourselves with the science and make it locally available.
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3.5. Applicability of the project

Even though an advanced growth of scissor type hydraulic car lift is observed today and
lifting and lowering is limited for our personal interests. We can apply to function in
industries directly in Automotive Production area.
Applicability of using scissor type hydraulic car lifter.
1. The main advantage of these lift over mechanism is that you rack a lot of travel in to a
small space in any scissor plat form.
2. Additionally used for moving vehicles from one floor to other floor very easily, for single
or multiple floor lifting.
3. Increase productive during assembly of double cabin pickup in different work station
because of its portability.
4. For ride on that are operator attended.
3.6. Project layout
The project divided in to four chapters the Thired chapter explains about introduction,
objectives, advantage of the project and problem definition.
Chapter two tries to discuss more on theory and literature review that has been done on
scissor type hydraulic lift design and fabrication. Chapter three focuses on the Design
analysis of individual scissor lift component.
Finally chapter four discusses the conclusion and recommendation of this project and
future work that can be done.
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CHAPTER FOUR
4. LITERATURE REVIEW
4.1. Background of the scissor lift
In basic terms, the scissor lift is platform with wheels that acts like a fork lift. In a
non-industrial setting, the scissor lift is useful for completing tasks which require the low
speed, mobility and transporting of people and material above ground level. The scissor lift is
unique in that it doesn’t use a straight support to raise workers in to the air. Rather, the
scissor lift plat form rises when the linked folding supports underneath it draw together,
stretching it up ward. When extended the scissor lift reached any where above the ground,
depending on its size and purpose. It can be powered by hydraulics traveling faster in the
middle of its journey and slower with more extension.
The first scissor lifts were built in the 1970s. Although improvements in materials and
safety has been made. Since then, the underlying basic design is often still used. The concept
was ideal for the many retail establishments that were beginning to expand their inventory.
As a relative to the forklift, the scissor lift boasted portability along with effectiveness. In
addition, they were the only industrial platforms that could be retracted and fit into the corner
of the office.
Modern scissor lift maintains a presence in nearly all aspects of manufacturing and
production, from construction to vehicle repair and beyond. Newer models can travel over
the flat surface of the ware house floor or the uneven terrain of a construction site. A scissor
lift does not go as high as a boom lift it sacrifices height for a larger work station. When
more height is needed boom lift can be used. There are a few different types of boom lift
each appropriate for different tasks. The electric boom lift to cable boom lift runs on
rechargeable batteries and is a commonly used in warehouses, because they can fit through
tight aisles, reach over equipment and onto high selves. Even when fully elevated, the
electric boom lift can be driven and moved throughout the warehouse. The towable boom lift
cannot be driven like the other models, but instead has to be towed behind a truck. The
towable boom lift is powered by either a rechargeable battery or a gasoline engine and is an
ideal model for rentals, it does have a high boom that rotates 360 degrees, making it easy to
reach a variety of areas once elevated. The articulating boom lift is perhaps the most versatile
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of all the boom lifts. It allows users to work at significant heights, if fully movable even
when extended, and is able to rotate a fully 360 degrees in every direction. Most models are
also narrow enough to be used in industrial settings and can be driven through narrow aisles
with ease.
Scissor lifts are used where less reach and height, but more workspace and lifting capacity,
are required. They are designed to provide larger platform work areas and generally to allow
for heavier load than boom lifts. Scissor lifts may be manicured in a manner. Similar to boom
lifts, but the plat form may be raised only vertically, except for an available option that
extends the deck horizontally. Modern scissor lifts make use of hydraulics to raise or lower
the lift table. Scissor lifts are available in both stationary and mobile platform. Scissor lifts
are available in both electrical and fuel power configurations. Scissor lifts are also available
for rough terrain work. Some scissors lift also boats of rigid arms to increase the stability of
the lift platform.. The big advantages of these types of lifts are less space work environments.
Most mobile scissors lifts are also equipped with speed limiters, so as to limit speed when the
deck is elevated. Most manufacturers offer trouble shooting diagnostics and several
additional options like foam filled tires powder deck extensions, additional power capacity to
increase maximum load, proper tank kits, self-closing entry gates, cold-weather kits and
extension deck. These lifts are often fond on many high schools, college and university
campuses for purposes of viewing videotaping or directing activities such as athletic, band
and theatre events and productions. Scissor lifts and other elevated work platforms are used
by workers to gain access to conduct work at heights.
However, scissor lifts can be dangerous when not properly maintained and serviced, used
inappropriately or used by an untrained operator. According to the federal bureau of labor
statics (BLS) censers of fatal occupational injuries (CFOL), nationally in 2009, 22workers
were fatally injured while operating a man lift. One of the most important aspects in the safe
operation of scissor lifts includes ensuring operators have received the appropriate training to
safely operate the equipment. Only trained and competent workers should be permitted to use
any scissor lift. To be effective, classroom-style instruction must be combined with a safe
operational procedure demonstration. Training must also be specific to the type of scissor lift
the employee will operate. Employers must stress the importance of workers to follow the
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established safe work practices and manufactures’ recommendations for operating scissor
lifts safely.
Training should include the following elements
1. Employer’s established safe work practices
2. Manufactures’ recommendations for safe operation
3. Hazards associated the scissor lift and worksite
4. Procedures for dealing with and reporting potentially hazardous situation
5. Trained demonstration of safe operational use of the lift
Lift must be visually inspected. Effective inspections are performed before each
work shift and after any occurrence that could affect the structural integrity of the equipment.
Foregoing regular scissor lift inspections has the potential to have life threatening
consequences.
Lift operators must walk around the equipment to ensure it is in good working order.
Operators must also review all safety devices, emergency controls, fall protection equipment,
the lift vehicles tires as well as other critical components. If the lift is equipped with
outriggers, they should adequately inspect for wear and damage and used in accordance with
the manufacturer’s recommendations, lift operators should report any equipment damage to
their supervisor immediately. Employers must review the equipments operator manually and
ensure employees do not operate scissor lifts in adverse weather conditions. All equipments,
including scissor lifts should be scheduled to and receive regular presentation maintenances
to ensure it is in good working condition. Repairs should be made to equipment as needed.
To ensure worker safety, equipment must be serviced in accordance with the manufacturer
recommendations. Using substitute parts or poor repair methods could result in equipment
failures, and thus lead to serious injury or death. Employers must consult and receive written
approval from the equipment manufacturer prior to making any modifications to scissor lift.
4.2. Definition of scissor lift
A scissor lift is a device that has a flat platform which can be raised straight up in
order to gain access and perform work on areas that are difficult to reach. A scissor lift is
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sometimes known as a table lift. Scissor lifts are raised on linked folding supports that draw
together to lift.
Scissor lifts are large pieces of sensational equipment that commonly used inside
warehouse, factories and on construction jobsites.
Scissor lifts allow workers to perform maintenance and other tasks at areas high above
ground level without having to worry about balance as they would while using ladder.
4.3. Classification of scissor lifts
There are most types of scissor lifting than people may think. Scissor lifts are mobile
elevated work platform (MEWP). Scissors lifts are commonly used to gain a safe working
environment to high locations of where ever you need to get too safety when working at
height.
Scissors lifts are used all over the world, and allow people to work safely at height every day.
Some of the lift tables will be discuses below.
4.3.1 Pneumatic scissor lifts
These types of lifts operate by making use of air pressure. As the mechanism to move the lift
up and down is powered by compressing and decompressing air. They are often less efficient
and definitely more environmentally friendly compared to the alternatives. The majority of
pneumatic scissor lifts does not need any electricity at all to power them and are safe to use
in most working environments and conditions. As long as there is a steady supply of air
available. They are good to go and cost effective as they do not require much in the way of
maintenance. But we did not select these types of scissor lifts in our design because the
working fluid is air as a result air is compressible and it is effective for rising loads for a
short period of time. And here we are going to design a lift that raises the automobile for
unknown period of time.
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4.3.2. Mechanical scissor lifts
Also known as diesel or electrical scissor lifts. These are by far the most commonly
used type of scissor lifts and are the ones you are likely to come across at work and operate once
you have taken part in scissor lift training. Electrical scissor lift are used in very enclosed spaces
where it would be far too dangerous to use diesel powered lifts are used for outdoor use mostly
and are usually able to be extended from around 10meters all the way up to 18meters. These
particular lifts extended using a rack and pinion or power screw system which converts radial
motion into linear motion. Their one drawback compared the other lifts mentioned above is that
because they rely on fuel or an electricity supply. The operational costs of these scissor lifts can
be on the expensive side.
4.3.3. Hydraulic scissor lifts
Hydraulic scissor lifts are another type of scissor lift that does not require electricity
to power them. The platform on hydraulic scissor lifts moves up and down as a result of
highly pressurized hydraulic oil bring pumped around it. There is something of a design flow,
particularly in order models, that because temperature can affect hydraulic oil in colder
weather the lift works slower than it does in warmer weather. This can be problem if you
need to use one during summer and winter months and world wide it may be worth operating
for a different type of scissor lift. In our design we select this type of scissor lifts because of
their working fluid (i.e. oil).hydraulic lifts are used when we need accurate positioning of the
load, we are going to lift the automobile for a long period of time and mainly oil is
incompressible fluid so, the load they lift doesn’t return suddenly
4.4 Scissor type hydraulic car lift mechanism
The hydraulic scissor lift depends on hydraulic pressure for raising, lowering and
maintain the plat form in an elevated position. The hand pump are located remote from the plat
form area, hydraulic cylinders that raise and lower the plat form are mounted on the pivoting
scissors support frame:
BAI Page 26
4.4.1 Cantilevered platform lift
The cantilevered platform lift system includes a tower containing the acme screw drive
mechanism and support for the cantilevered arms that raise or lower the lift plat form all system
apparatus is located in the tower with the exception of a stabilizing base from which extends to
the full dimension of the platform.
If we built a scissor lift with one “tier” you can also build a scissor lift with several
tiers. Keep in mind that the bottom tier must be strong enough to hold up the entire scissor lift,
plus any weight on the plat form. Also consider that there is a rotational limit as to the height to
width ratio of any raised plat form doesn’t make the scissor plat form too narrow when extended,
or it will fall over.
Due to the physical involved, each arm in the scissor lift must hold roughly weight of
the plat form however; each beam must suffer a shear stress that is the equivalent of supporting
half the weight in the middle of the beam, with support at each end. As such, you must design
beams that are strong enough to handle this. The most common form of power used in scissor lift
as noted above, is hydraulics. This is not only option a regular motor will work too but hydraulic
can push a lot of force quickly and accurately, so these system are favored in general, the
hydraulic are attached as shown in the attached picture. The piston is attached to one end of the
base, and the piston rods are attached to a point, slightly off center from the middle of the
opposite rod. The exact point of attachment is important because it affects the amount of force
you need to exert in order to being to raise the lift. Notice that with the arrangement, it requires
much more force to raise the lift the first few degrees, and much less force after that to determine
how much force you need, simply look at the angle of the pistons when lift is collapsed the force
needed will be equal to the weight of the lift times the sin of the piston angle. This point is why
the positioning of the attachment point is so important, keep in mind when designing your lift.
In order for our original wheel locking design to work is below figure our hydraulic
lift would need to be rewired in order to engage the plat form as it travels both up and down. The
original locking was modeled with the intention that the wheel would be attaché to the top of the
lift so that they would rise with the lift as it moved up. Then the wheel would raise the base of
the lift off the ground as the lift traveled down to its collapsed position. Currently there is a flow
BAI Page 27
control valve in place which limits the flow of hydraulic fluid to the extending motion of the
piston. If this was removed and the motor rewired to allow the piston to move in both directions
under pressure our original locking mechanism would become feasible. To do this we suggest
hiring a professional electrical hydraulic specialist or simply purchasing a scissor lift which
requires hydraulic pressure for both the extending and refracting modes.
To make it easier to lock and unlock the wheels we would supplest for a future design to
include wheel with more prominent locking pedals. This design aspect is limited by the size of
the wheel openings under the lift.
4.5. HYDRAULIC SYSTEM COMPONANT
2.5.1 Hydraulic pumps

The sole purpose of a pump in hydraulic system is to provide flow, a pump which is the
heart of hydraulic system, convert mechanical energy in to hydraulic energy. While
mechanical rotational power is the product of torque and speed, hydraulic power is
pressure time flow. The pump can be designed in such a way that either flow or pressure
is fixed, while the other parameter is allowed to swing with the load. In other words, by
fixing the pump flow the pressure goes as the load restriction is increased, conversely the
flow goes down with an increase in load restriction when the pump delivers fixed
pressure.
Pumps can be classified as
1. Non positive displacement (hydrodynamic) pump
2. Positive displacement (hydrostatic) pump.
1. Non positive displacement pump
- The pressure produce, is proportional to the rotor speed used for low pressure and
high volume flow application.
- Maximum pressure capacity is limited to 17 – 20 bar (20-30kgt/cm2)
- Used for transporting fluid
- Pressure relief valve is not required
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- Cost less and operate with little maintenance because of few number of moving
parts \when the resistance of the external system becomes very large the pump
will produce no flow and thus its volumetric efficiency become zero
o Example:- the centrifugal and axial pumps
2. Positive displacement or hydrostatic pump
- As the name implies, these pumps produce a constant put per revolution of the
shaft.
- A majority of the pumps used in fluid power application belong to this category.
- Capable of overcoming the pressure that results from the mechanical loads on the
system as well as the resistance to flow due to friction.
- Output flow is constant and not dependent on system pressure.
- The pressure out put up to 680 bar
- High-pressure and low pressure areas are separated and hence the fluid cannot
leak back and return to the low-pressure source.
- Require pressure relief valve.
Example: Gear pump, vane pump, piston pump.
Pump comparison
Type Variable Efficiency (%) Pressure range cost

displacement (bar)
Gear No 90 150 low
Vane Yes 95 250 Medium
Piston Yes 98 >500 High
Table-1
4.5.1A. DOUBLE ACTION HAND PUMPS
The double action hand pump is used in some a few newer systems as a backup
unit. Double action hand pump produced fluid flow and pressure on each stroke of the
handle. The double acting hand pump consists of essentially of a housing which has a
cylinder bore and two parts, a piston, tow spring loaded check valve and an operating
handle. An o-ring on piston seals against leakage between the two chambers of the piston
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cylinder bore. An O-ring in a groove in the end of the pump housing seals against,
leakage between the piston rod and housing.
4.5.2 HYDRAULIC CYLINDERS

A hydraulic system is generally concerned with activities related to moving gripping or
applying force to an object. Activators are interface components that convert hydraulic
power back to mechanical power. Based on whether an actuator gives rotational motion
or linear motion.
Activators are basically categorized as
- Rotary activators and
- Linear activators
- Rotary activators are hydraulic motors
o Pumps perform the function of adding energy to hydraulic system for
transmission to some remote point, while motors do precisely the opposite
- Linear actuators, as the name implies, are used to move objects or apply a force
in a straight line.
o Their function is to convert hydraulic power into linear mechanical power
o Application include pulling, pushing, tilting and pressing hydraulic
cylinder are further classified as:
 Single acting cylinders and
 Double acting cylinders
o Single acting cylinder
- Single acting cylinders are pressurized at one end only while acting cylinders are
pressurized at one end only while the opposite end is vented to the atmosphere or
tank.
They are usually designed in such a way that a device such as an internal spring
retracts them. The top below show simplest form of single acting hydraulic
cylinder.
Fig. 7
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the force applied by the piston depends on both the area and the applied pressure.
This force applied for a given cylinder can be calculated by the equation:
F=PxA where F is force applied in N
P is the pressure in Pascal or bar and
A is the cross sectional area of the cylinder.
o Double acting cylinder

Double acting cylinders are the most commonly used cylinder in hydraulic
application, pressure can be applied to either port giving power in both directions.
The difference in effective area caused by the area of the rod that reduces the piston
area during retraction, since more fluid is required to fill the piston side of the
cylinder during extension, the operation is slower. However because of the greater
effective area, more force is generated on extension, during the retraction operation
the same amount of pump flow will retract the cylinder faster because of the reduced
fluid volume displaced by the rod.
Fig .8
4.5.3 SELECTOR VALVE

Selector valve are used to control the direction of movement of an activating unit.
A selector valve provides a path way for the simultaneous flow of hydraulic fluid into
and out of a connected activating unit, as elector valve also provided a means of
immediately and conveniently switching the direction in which the fluid flow through the
activator, reversing the direction of movement.
4.5.4 RESERVOLRE
There is a tendency to envision a reservoir as an individual component. In line

type has its own housing is complete with in itself and is connected with other
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component. In reservoir a space in provided in the above normal level of the fluid, for
fluid expansion and the escape of entrapped air. Reservoir are never internationally filled
to the top with fluid most reservoir are designed so the rim of the filler neck is somewhat
below the top of the reservoir to prevent over filling during servicing most reservoir
equipped with dipstick or glass sign gape by which fluid level can be conveniently and
accurately checked.
4.5.5. HYDRAULIC FLUID
Types of hydraulic fluid basically four used in hydraulic power system
- Vegetable base
- Mineral base
- Synthetic hydrocarbon base
- Phosphate ester base
Except as noted, this fluid is not compatible with each other, and you must be able to identify
each of term and understand their advantage and limitation.
Vegetable base: - Mil – H 7644 vegetable base fluid was used in the past when aircraft hydraulic
system requirement were not nearly so severs as they today.
Mineral base:- MIL H-5606 mineral base hydraulic fluid is still widely used for aircraft hydraulic
and other power system. A kerosene type petroleum product that has good
lubricating characteristics it contains additives that inhabit forming and keep it
from reacting with metal to form corrosion.
Synthetic hydrocarbon base: - the familiar red oil as mil – H-5606 is commonly known is being
replaced in some military aircraft with mil-H-83282 fluid.
Phosphate ester hydraulic fluid
Mil-H-5606 hydraulic fluid can create a fire hazard mean easily flammable if line breaks
and sprays the fluid out under high pressure into the near area of operation.
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CHAPTER FIVE
5.DESIGN OF SINGLE SCISSOR JACK

5.1. Dimensional analysis (synthesis)
Weight W=18639N (1900kg when it is fully loaded)
Max height H=1800mm
Min height h=200mm
Max length of cap (base) =5000mm
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Max width of the scissor jack=800
Figure.9
The reason that we select point 1 and 4 to be pin joint is because of the weight of the automobile
near the cab is greater than that of the space used to carry load. The weight near the cab is greater
because of the presence of engine. In our design we are going to design the scissor jack when it
is fully loaded i.e. when it is full of oil, fuel, &when it is loaded with some of accessories of the
automobile
 Point 1, 3 and 4 are fixed joints i.e. they are pin joints
 Point 2 and 5 are roller connections
In order to simplify our problem of assembly of the link with the cap and base we should have
some constants on the cap and base from the center of the pin to the upper plate of the cap and to
the lower part of the base.
Assumption
 The distance from the ground of the base to the center of the pin 1 and from pin 2 to the
top of the cap is taken to be 60mm
 The distance from pin 1 to pin 3 and pin 3 to pin 2 is the same.
 The angle of the link with the horizontal is taken to be ϴ.
 The max angle is taken to be 45 0
When the jack is at its maximum lifting height:

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60mm+x+60mm=H
60mm+x+60mm=1800mm
x=1800mm-120mm
x=1680mm
When the jack is at its minimum lifting height:
60mm+x+60mm=h
60mm+x+60mm=200mm
x=200mm-120mm
x=80mm
Figure.10
x
sin ϴmax =
l
x 1680
l= =
sin ϴmax sin 45
l=2375.88 mm
When ϴmax = 45………………… l=2375.88 mm ;
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Fig .11
2375.882=1680 2+ x 2
x 2=2822405.774
x=1680 mm
X=length (distance) between the 2 pins i.e. between pin 1 and pin 5, when it reaches its max
lifting height
To find minimum lifting angle
Fig..12
80
sin ϴ min = =0.03367
2375.88
ϴ min =sin −1 ( 0.03367 )

= 1.929
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͌ 20
Fig .13
2375.882=802+ y 2
y 2=5638405.774
y=2374.53mm
y=lengt h ( distance ) ¿ pin 1 ¿ pin5 w h en it isat its minimumlifting h eig h t .
 From the above calculation we can see that y can be taken to be the minimum length of
the cap(base)
 See the difference b/n x and y, say it is A
A=y–x
= 2374.53 – 1680
= 694.53mm
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5.2. Force Analysis
The load is uniformly distributed all over the length of the cap. To see the distribution of the
force all over the length of the cap assume the load to be concentrated at the center
piston
F=force exerted by t h e h e link F
t
W = weight of the pick up when it is fully loaded

l=lengt h of t h e link=2376mm
 Total mass= 1900 Kg :
W= mg
= 1900x 9.81
= 18639N
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Fig .14
- is the angle b/n the horizontal and link and varies from  min to max
 Static condition
 ∑ Fx=0
B x +Ax-F=O
B x +Ax =F ………….(1)
 ∑Fy=0
Ay+Cy = w/2
 Taking Moment about A: + ∑ MA= 0
w/4 *L*cos - B x * x= 0
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Fig.15
 x- Varies with i.e. when  increases x- increases
But the maximum Bending moment occurs when  is minimum Mmax at  =20, then
x will be x = 80mm, and L= 2375.3mm≅2376mm
W/4 *L Cos = B x * x
W
∗LCOS 18639
Bx= 4 …………………...................but w/4 = =4659.75N
4
x
= 4659.75*2.37453m*Cos2
0.08m
B x = 138224.698N
 Ay + cy = w/2
W/4 +w/4 = w/2
 B x +Ax = F , Fpr2 = 285878N= F
A x = 285878 – 138224.698
A x = 147653.3 N
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5.3. DESIGN OF LINK
Due to the applied force on the links, the links may buckle in to planes at right angle to each
other. For bucking in to vertical plane (i. e. in the plane of the links). The links are considered
as hinged of both ends for bucking in a plane perpendicular to the vertical plane, it is considered
as fixed at both ends. All the links undergo compression.
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Fig.16
-is minimum angle
 We are going to design the link when it is at its

minimum position because max. Bending moment Occurs in it is minimum position.
 We have a total of four links in the Jack, since the entire link is similar in shape, size and
appearance; therefore we are going to do the design for single link.
Assumptions:
 Homogeneous property
 Isotropic material ( material that have the same property in all direction)
Analysis:
Transform this inclined link to a horizontal to see clear effect of the force in the link.
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Fig.17
min = 20
 Taking moment about A: + MA=0
-w/2 * L/2 Cosmin + w/4 * L/2 Cosmin = 0
9319.5 * L/2 Cos2 + 4659.75* L/2 Cos 2 =0
 Taking section y-y (section between A&B)
FIG.18
M (L/2 Cosmin)….. M 1 -W/2*X=0
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M 1 =W/2*X…..(X= L/2 Cosmin)
I hollow = bh3 _ (b-t)(h-t)3
12 12
Fig.19
 =MC/I…………………………M=Bending moment
I=moment of inertia
C=h/2
Hollow bar selection for link design
Size Thickness(mm) Area of section(cm2)

H(mm) B(mm)
100 60 4 12
100 60 5 14.7
100 60 6 17.4
100 60 8 22.4
Table-2
 From the data given in table 2 we select:

 h= 100mm
 b= 60mm
 t= 6mm
I hollow = (0.06) (0.1)3 – (0.054) (0.094)3
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12
I h ollow = 1.26*10-6m4
M max= 5532.41N.M
C= h/2 = 100/2 = 50mm = 0.05m
 And we know that Design Stress is given by: ❑D
MC
❑D = = 5532.41*0.05
I h ollow
1.26*10-6
D= 219.5 N/mm2
From our Design stress, we can select our design material:
Metallic process ultimate yield

Material (condition ) strength strength
RQC- 100a HRb plate 931 N/mm2 883N/mm2
Table.3
Take F.S = 2
M 1– w/4 *x= 0
M 1= w/4* x
M 1(x=0) ____ M 1=0
2.376
M 1 ¿ x= L/2 Cosmin) = w/4* *Cos 2
2
= 5532.41 Nm
 Taking section x-x(between B& C)
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Fig.20
M2 – w/4 *x+ w/2 (x- L/2 Cos2 ) =0
M2 = W/4 *x – W/2 ( X- L/2 Cos 2 ) @x= L/2 Cosmin
M2= w/4 * L/2 Cos 2
= 5532. 41 N
M2 = w/4 *x- w/2 (x-L/2 Cos2)
= w/4 (L Cos) – w/2 ( L Cos 2 – L/2 Cos 2 )
=w/4* L/2 Cos - W/2 ( L/2Cos 2)
M2 =0
M max= 5532. 41 Nm
Shear force diagram
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Bending moment diagram
Fig.21
 Let’s check our material weather it is safe or not
y= 883 F.S=2
y 883
all= =
F .S 2
= 441.5N/mm2
all > D
441.5 > 219.5 N/mm2 ……………………………..safe
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5.4. DESIGN OF PIN
The pin is one of the most important part of the Jack. The pins support the load that is
transferred to the links. All the pins help us to have good transformation of motion of the link.
 The pin mainly fails by shear.
FIG.22
 There are at least 6 pins in the Jack If we design for pin 3 all other pins will be the same.
We are designing pin 3 because maximum load is transformed by pin 3.
w/4
sin88 =
Fpin
F pin= w/4 *sin 88
F pin= 4656.91N
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 Sincepin3isundersingleShear: :
Fig.23
F π dp 2
τ= …………… Ap=
Ap 4
 τ = 4F / πdp2
F= Force in the pin
d p= pin diameter
τ = shear stress
Ap= area of the pin
(All other pins except pin are in double shear; therefore we get a max diameter in single shear i.e.
no need to design the other pins)
Assumption:
 load is uniformly distributed throughout the length of the pin

 the pin have a uniform cross section
 neglect bearing stress due to link holes
Material selection:
The material used should be high in strength
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Material ultimate yield strength
Strength ult y
Malleable Cast 1ron 276MPa 207MPa

ASTM A 197
Table-4
Analysis
Take a factor of safety, n = 2
y
all = = 207 = 103.5 N/Mm2
F .S
2
τ all= 103.5 = 51.75N/mm2
2
τ all= 4 Fpin
πdp2
πdp2 = 4 Fpin = 4*4656.91

πdp2 π*51.75
d p= 10.7mm
 Take the diameter of the pin to be 11mm

 Now check the pin for shear
τ = 4 Fpin = 4*4656.91
πdp2 π (11 )2
= 46N/mm2
Thereforeτ all > τ
51.75 > 49 ………safe
 Total Dimension of the pin:
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Height of head = 0.5* 11= 5.5 mm
Diameter of head = 1.5*11= 16.5mm
Fig.24.
 Length of the pin (L) depends on the dimension of the Hollow rectangular bar used for
link design
L pin= 2*60+2t was h er + clearance
=120+ 2*1.65mm + 40mm
=163.3mm≅ 164mm
 t washer =1.65mm
 Length of the pin for the roller = 79mm
 Length of pin for pin joint =164mm,60mm(for pin 1&pin4)
5.4.1. Selection of washer:
A washer is a cylindrical piece of metal with a hole to receive the bolt (pin). It is used
to give a perfect seating for the nut (pin) and to distribute the tightening force uniformly to
the parts under the joint. It also prevents the pin from damaging the metal surface under the
joint.
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Fig.25
From fig.19 dimension of the washer becomes:
D=pin diameter
 Inner diameter=D+1=11+1=12mm
 Outer diameter=2D+4=2*11+4=26mm
 Thickness=0.15D=0.15*11=1.65mm
5.4.2. Selection of pin lock:
There are different types of pin lock, but for our design we have selected split pin lock. A
split pin, made of steel wire of semi-circular cross-section is used for locking the pin. In this
arrangement, the split pin is inserted through a hole in the pin body and touching just the bottom
surface of the pin. Then, the ends of the pin are split open to prevent it from coming out while in
use.
 Split pin diameter (SD)=0.2D
D=diameter of pin
SD=0.2*11mm
=2.2mm
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Fig.26 application of split pin
5.5. Design of Cap and Base
In the design of cap and base the major criteria is their thickness. The load that acts on the
cap is assumed to be uniformly distributed all aver the length of the cap or all aver the area we
consider crushing stresses induced.
It is assumed to be the surface of the cap is rough in order to have a good surface contact
between the cap and button part of the automobile.
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Fig.27a
Fig.27b
 First calculate the reaction forces

1. Ax = 0
Ay + By – w/2 L =0
Ay + By = W/2 L
 Taking moment about A: +MA = 0
wL
By L – (L/2)= 0
2
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wL2
By L=
4
WL
By =
4
WL
Therefore: Ay+By=
2
WL WL
Ay + =
4 2
WL WL
Ay = –-
2 4
WL
Ay =
4
Fig.28
 Taking section a-a
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Fig.29
 -V 1 + wL/4=0
V 1=WL/4
wL
 Taking moment about +M a-a M1 - *x= 0
4
wL
M 1- *x=0 ……………………… @x=0,L/2
4
M 1@X=0...... M 1=0
M 1@X=L/2...... M 1=WL/4*L/2
2
M 1= WL
8
 Taking section b…b
Fig.30
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WL wL
 -V 2- + =0
2 4
wL WL −wL
V 2= - =
4 2 4
 Taking moment about b-b
wL WL
M 2+ (x-L/2 ) - (x)=0
2 4
WL wL
M 2= (x)- (x-L/2 ) …………….@x=L/2,L
4 2
WL
M 2= (L/2)-0………………..@x=L/2
4
2
M 2 = WL
8
2
wL
M 2 = WL - (L/2) …………………….@x=L
4 2
2 2
M 2= WL - WL =¿0
4 4
M 2=0…………………………………@x=L
Shear force and bending moment diagram
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Fig.31a. Shear force diagram (SFD)
Fig.32b. Bending moment diagram (BMD)
WL2
From the BMD, maximum bending moment is M max=
8
 Now calculate L:
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Fig.33 a. b.
Cos 20 = L/ 2376 L= 2376Cos2
L=2374.55mm≅ 2375 mm
M max= 18639N*(2.37455)2
8
M max=13137N.m
Take the cap to be a bar (solid)
For clear understanding magnify the drawing
Fig.34 a. b.
 From bending of pure member
=MC/I
3
I solid = h b ………. h=t
12
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M max c
D = ………M= bending moment
I
I= second moment of Inertia
C= h/2
❑D = Design stress
 I for solid part of Rectangular cross section is given by:
3
I solid = h b
12
 Take the cap to be rectangular plate with a thickness of 8mm and a width of 800mm
I solid = 0.8*(0.008)3 b= 800mm=0.8m

12 h= 8mm=0.00mm
=3.413*10-8 m4
M max c
D = ………………… C= h/2 = 8/2 = 4mm
I
=0.004m
❑D =13137 N . M ¿(0.004 m) ¿
3.413∗10−8 m 4
=1.53949*10-9m2
=1539.4N/mm2
 Now select a material : To do that
Assume F.s to be = 1.5
all
n= ❑ ………………………………………n=factor of safety
D
Consider a material
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AISI Steel Condition Yield strength Elongation Machinability
Designation MPa %
S-5 Tempered 2050c 2344 5 Medium to high
Table-5
y
all =
F .S
=2344
1.5
=1562.66N/mm2
Therefore: all>  D---------- safe
 Total dimension of the plate :
Cap Base
Length=2575mm Length=3366mm
Width=800mm Width=800mm
Thickness=8mm Thickness=8mm
Table-6
5.6. Design of piston Rod
Short composition member subjected to centrally applied and may be designed on the
bases of direct compression. However long columns where slenderness ratio is greater are
classified as critical load. Safe load is the actual load which a column can stand safely. But here
the piston rod is subjected to fluctuating stress imposed due to variable load for different
positions of the hydraulic scissor jack.
The piston rod experiences a maximum stress at the start of its lift, of the same nature with in a
cycle.
BAI Page 61
Fig.35
Where ❑max= maximum stress
❑min= minimum stress
❑a= stress amplitude (alternating stress)
❑m= mid range stress
❑max +❑min
m =
2
❑max −❑min
❑a=
2
When the link is at its minimum position of θ=20 from the horizontal the compressive force is
the exact weight of the cap, links & the car The piston rod is placed horizontally.
 F= weight to be carried by the piston to get this we know that the mass of the automobile
is 1900kg, but the piston does only raise the automobiles mass but also the mass of the
cap & mass of the links. Therefore we need to assume that
m cap= 50kg
m link = 21kg per each link then = 21*4=84kg (for all links)
BAI Page 62
F= (m car + mcap + mlink ) *9.81
= (1900+50+84)*9.81
F= (2034)9.81
= 19953.54N
 Since we are going to use two pistons to perform our task
19953.54 N
F/2 (per each piston rod) =
2
=9976.77N
 To get the length of the piston
When θ is minimum the distance between pin 1 and pin 5
Fig.36.a & b
x
Cos 20 =
2376
X= 2376 Cos 2
X=2374.55mm
When θ is maximum the distance between pin 1 and pins 5 is
BAI Page 63
Fig.37
y
Cos 45=
2376
y= 2376Cos 45
y= 1680mm
 To get the retract distance (the length of the piston rod)
L pr = x- y
=2374.55-1680
=694.46mm
But this length of the piston rod ¿ ¿)is not the exact length. The length is the length that
comes out of the cylinder there fore we have to have a length (distance) out of the cylinder for
assembly purpose.
Take the length of the piston rod out of the cylinder to be 30mm. Also this length amount totally
come out the cylinder in order to reduce the effect bucking. Therefore 20mm of the piston rod
does not come out of the cylinder
Therefore, the Total length of the Piston rod becomes.
L pr = 694.46 +30+20
L pr = 745mm
This length of piston rod doesn’t include the thickness of the piston head. But to make our
calculation easier, neglect the thickness of the piston head.
BAI Page 64
Fig.38
 From the above statements we can see that the Height of the cylinder ( H cy ) is
H cy = 745mm+6mm (thickness of the cylinder)
H cy =751mm
P=9976.77≈9977N----applied load
Assumption:
 Marine factors – K a (load correction factor) =0.8
¿ K f ¿ Fatigue stress concentration factor) =1.6
1
- K e (fatigue strength reduction factor)= =1/1.6=0.66
Kf
Assume other factors (kc, kd, kb) to be unity
Material selection:
Due to the nature of the load acting on the piston rod the material select is heat and corrosion
resistant.
Material Tensile strength Yield strength Modulus of

Classification MPa MPa Elasticity E
BAI Page 65
(Gpa)
Martenstic 1241 965 21
AISI 610, H-11
Table-7
Analysis
 When θ is maximum
Fig.39
 Compressive force on piston rod= F pr 1
9977
Sin 450 =
F pr 1
9977
F pr 1=
sin 45
= 14109.6N
 When θ is minimum
BAI Page 66
Fig.40
9977 N
Sin 20 =
F pr 2
9977
F pr 2= = 285878N
sin 2
From F pr 1 and F pr 2 we can see that the maximum stress is at the minimum angle i.e. when it
starts to lift the car
Since the Piston rod is circular in shape, the cross sectional area is given by :
A= πd2
4
πd2
 max * = F pr 2
4
max = (285878)*4
πd2
= 363991.23
d2
 ❑min* π d 2 = F pr 1
4
min = 4(14109.6)= 17964.9
BAI Page 67
πd2 d2
❑max +❑min
And also m =
2
=363991.23 + 17964.9
2d2 2d2
m = 181995.58 +8982.45
d2 d2
m = 1¿ d 2 *(181995.58+ 8982.45)
m = 190978
d2
❑max −❑min
a = a =¿ 363991.23 -17964.9
2
d2 d2
a =¿173013.13
d2
Since the material we select is highly resistant to compression
 Factor of fatigue stress concentration , K f = 1.5
 Crippling stress ❑c= 550
 Take Rankin’s constant, ∝ = 1/ 1500
 It is known that , K a = 0.8
 K e = 1/ K f = 1/1.5 = 0.66
The maximum safe stress which can be applied to the load to the piston rod while working is
given by
Se = ½ * (marin factor products)*❑ y
= 0.5 *¿) * ❑ y
BAI Page 68
=0.5* 0.66*0.8*965
=254.76 N/mm2 (MPA)
Where Se = fatigue or endurance strength
Now take factor safety to be 2
 From Good man safe stress:
1 ❑a
= + m
SF Se ❑y
½= 173013.13 + 190978
d2 d2
254.76 965
0.5 = 679.12 +197.9
d2 d2
0.5 = 1(877)
d2
877
d2 =
0.5
d2 = 1754
d= 41.88mm
Take the diameter of the piston rod to be 42mm
 To check safety of our design
From Euler’s formula:
Consider the piston red as a column fixed at one end & free at another end
1st the hydraulic system is considered to be fixed at one or bottom and free top end with applied
load p = 9977N
BAI Page 69
Fig.41
 From Euler’s rule for column with one fixed and one free end
Le= 2L
L= length of the column
π 2 EA
Pcr =
(¿ / k)2
Pcr = critical load
E= modulus of elasticity = 21000N/mm2
A= area of the piston rod
Le = effective length = 2L
K= radius of gyration
 Cross sectional area of the piston rod
A= π (42)2
4
=1385.44mm2
Le = 2 L pr
 Assume the thickness of the piston head to be t h ead= 30mm
L pr = 745mm
BAI Page 70
Le = 2 L pr
=2*745
=1490mm
 For circular cross section moment of inertia is given by
πd4
I circular solid =
64
π (42) 4
=
64
=
152745mm4
I
K=√ ( ) = 152745/1385.44
A √
=√ 110.25 mm 2
= 10.5mm
π 2∗21000∗1385.44
Then Pcr =
(1430/10.5)2
Pcr = 15481.5N
Therefore Pcr > P ----safe
BAI Page 71
5.7. SELECTION OF HYDRAULIC SYSTEM
Since we did design the piston rod of the hydraulic system by making use of the piston rod
diameter as a starting point we can select the hydraulic system.
5.7.1 Specification of the job
From the previous calculations we know that
Force requirement of the job is
F= mg
mT = total mass ie. Mass of car plus mass of cap plus mass of link
m T = 2034kg
F= (2034)9.81)
=19953.54N
5.7.2 Length of the stroke

L= 745mm; this length is related with the maximum lifting height and is taken that 1800mm
5.7.3 Speed of piston rod and head assembly

Take minimum time taken for full stoke of the piston rod to be 90seconds. The speed is
therefore:
BAI Page 72
Speed = L/t = 1.8m /90sec.
= 0.02m/sec.
5.7.4 Cylinder size Determination

Cylinders are linear actuators which converts fluid power in to mechanical power. Most
of the cylinders are used to carry pressure. There are two major types of cylinders. These are
1. Thin cylinders:-if the thickness of the wall is less than 1/15 to 1/20 of its internal
cylinder. t/di<1/15-1/20
2. Thick cylinder: - if the thickness of the wall or if the ratio of thickness to internal
diameter is more than 1/20. t/di>1/20
The internal pressure for the cylinder is equal to fluid pressure, pressing the piston
head .a proof for this is fundamental principle of fluid called Pascal’s principle, Pressure
at a point in a fluid closed container is the same in all direction .
Most standard hydraulic cylinders are designed to carry on internal pressure of 50bar
to 200bar. The fluid pressure is uniformly distributed all over the diameter of the piston
head.
Internal diameter of the cylinder is equal to the diameter of the piston head. Hydraulic
cylinders carrying fluids at high pressure develop both radial and tangential stresses with
valves that are dependent up on the radius of the element under consideration.
 Assumption –longitudinal elongation is constant around the circumference of the

cylinder. The hydraulic cylinder is assumed to be thick from this assumption take the
thickness of the cylinder to be 6mm.
 Select the cylinder to be double acting cylinder

 Piston rod diameter is calculated that d rod = 42mm
 Select the bore diameter of the cylinder to be twice that of the piston rod
Cylinder Bore diameter = 2*d rod
= 2* 42
BAI Page 73
= 84mm
Area of piston rod: A pr = πr 2
= π(21mm)2
= 1385.44mm^2
 Now calculate the pressure, we know F=9977N
P= F/A= 9977/1385.44
=7.2N/mm2
= 72bar
 This is total pressure due to the whole weight of the scissor jack including weight of the
automobile, except that of weight of the base .So the pressure applied by the pump should
exceed the above pressure and for this reason use a pump with pressure of 100bar.
Material selection:
AISI UNs Treatment Tensile Yield Elongation in

No. No. Strength strength 50mm, %
MPa MPa
1010 G10100 Hot- Rolled 320 180 28
Table-8
Analysis:
Taking F.S to be 2
❑y 180
❑all= = = 90N/mm2
FS 2
all
τall = = 90 = 45 N/mm2
2
BAI Page 74
While we are dealing with hydraulic cylinders, we mainly deal with two stresses
1. Hoop ( Circum frenetically) stress- stress along the thickness of the cylinder for thick
cylinders hoop stress is different along the thickness, it is maximum at the inner diameter and
minimum at the outer diameter
P di
❑h oop=
2t
P= pressure inside the cylinder
d i = inner diameter of the cylinder
t = thickness of the cylinder
❑h oop = hoop stress
2. Longitudinal stress(❑L)-stress along the length of the cylinder

 Is half of hoop stress
❑L=0.5* ❑h oop
 Now let’s calculate hoop stress (❑h oop ¿
❑h oop= Pdi =
100∗42
2t 2∗6
=700bar
=70Mpa= 70N/mm2
 ❑L=0.5* ❑h oop
=1/2 *70N/mm2
= 35N/mm2
From there calculations we can see that
all > ❑h oop> ❑D
BAI Page 75
Therefore our design is safe
 Dimension of the cylinder:
t= 6mm
d i= 84mm
Do = d i +2t
=84+2(6)
=96mm
5.7.5 Capacity of pump needed
 Maximum piston speed: s= distance
L= length
t=time
1800
V= s/t = L/t =
9 0 sec
=0.02m/s
 Flow rate Q= A*V
=A*s/t A=A pr = πr 2
=1385.44mm2
= 1.385* 0.02m/s
=2.77*10-5m3/5
=0.0000277m3/s
[1L=10^3m3/s]
 For 1L = 10-3 m 3/5
BAI Page 76
X= 0.0000277m 3/5
X= 0.0277 l/s
Q= 0.0277l/s
5.7.6 Efficiently of pump
The type of pump selected is gear pump with efficiency of 80-90
5.7.7 The size of electric motor needed
 We can calculate the power of the electric motor in two different ways.
1. Power=force*Velocity
2. Power=pressure*flow rate
1. P=FV=9977N*0.02m/s
= 199.54watt
2. Power required to run the pump is calculated as power = pressure * flow rate
=100N/mm2 * 0.0000277 3/5
=160*106N/m2*0.0000277m 3/s
=2770 watt
=2.77kw
From these two calculated powers take the larger one for better application i.e. =2770watt
[1
hp= 746W]
 1hp = 746w
X? =2.77kw
BAI Page 77
X= 2770 =3.713hp …….select a motor with this power
5.7.8 Reservoir needed
Reservoir size should be 2.3-3 times the pump capacity (l/min). Pump capacity is 0.0277 l/s and
this becomes 1.662 l/min. So the reservoir size is taken to be
2.5 * 1. 662 l/min
Reservoir size = 4.155L
 The scissor Jack we are designing can be operated manually and electrically. We did this
as per request of the company electrically and we are deigning it to be operated manually,
if there is shortage of electricity.
Table for selection of scissor Jack that operate manually and electrically.
Manually Electrically
1 Link length L= 2446mm L=2446mm
2 Link dimensions H=100,B=60, t=6 H=100, B=60, t=6
3 Pin dimensions Dp=11, Hh=5.5
Dh= 16.5. Lpin =170
4 Cap dimension t=8,w= 800 L= 2575
5 Base dimension t=8, w = 800 L =3335
6 Hydraulic system Drod = 42, Dic= 84 mm
Doc = 96mm, Lrod = 745
Reservoir size 4.155L
7 Electrical system P= 3.713hp
Q= 0.0277L/s V=0.02m/s
P=70MPa
Table-9
We can select or manufacture the jack based on the above criteria
BAI Page 78
5.8. Selection of bearing
Bearing are manufactured to take radial loads, pure thrust load or a combination both kinds of
loads. There are four essential parts of bearing. There are the outer ring, inner ring, balls (rolling
element) and separator.
 Types of bearing
 Ball bearing- capable of high speed
-only carries radial force (load)
 Roller bearing - carries radial & thrust force (load)
-Capable of carrying greater load
 Generally bearing can be classified in to
A. Roller contact bearing
In which load is transferred through elements in rolling contact
e.g. ball & Roller bearing
B. Sliding contact bearing -
In which there is a direct sliding load – carrying members on its support
e.g. Journal bearing, sleeve ……….
BAI Page 79
Based on the load they transfer rolling element bearing can be categorized in to
 Radial -carry Primary radial load

 Thrust / axial contact -carry Primary axial loads
 Angular contact-carry axial and radial loads
For our design we have selected a Roller bearing – angular contact based on its load carrying
ability.
 Since Bearings are assembled by force – fit, therefore, the inner diameter of the bearing is
selected to be 11mm, exactly the same with the pin diameter.
Now find the outer diameter (OD) of the bearing and width
To do that
Bore (mm) OD(mm) Width (mm)

10 30 9
11 X1 X2
12 32 10
Table-10
From the above table calculate x1 and x2
Bore(mm) 00(mm)
10 30
11 X1
12 32
Table-11
12-10 =32-30
11-10 x1-30
3 = 2
1 x1-30
2x1-60=2
2x1=62
BAI Page 80
X1=31mm
Bore(mm) Width(mm)
10 30
11 X2
12 10
Table -12
12-10 =10-9 2=1/x2-9
11-10 x2-9
2 x2-18=1
2 x2=19
x2=9.5mm
From the previous Calculations, select a Roller bearing Angular – contact that have the following
dimensions:
Bore(mm) OD(MM) Width(mm)

11 31 9.5
Table-13
If you didn’t find this bearing with the recommended dimensions please select bearing with
OD=32, Bore=12 & width of 10mm.
BAI Page 81
5.9. Hydraulic hose selection
Users often select hydraulic hoses based on the working pressure of the system. However other
factors can dramatically affect hose assembly life. The following should be considered in the
selection process:
3.9.1 Single wire braid versus double wire braid
Using high-tensile wire, single wire braid hoses will often have adequate working pressure
for many systems. However, if used outside, cover damage that exposes the braid will result in
corroded wires and hose failure. An extra braid separated by a rubber layer greatly extends hose
life at a small premium.
Fig.42
5.9.2 Compact hoses versus standard hose
Modern manufacturing equipment allows single and double wire braided hoses to be
manufactured to exacting tolerances. This process control has allowed the development of
products with thinner covers and tubes, resulting in products with reduced weight, increased
BAI Page 82
flexibility and, reduced cost. However there is a trade-off. Thinner covers mean that the hoses
are more easily damaged by abrasion, if the braid is exposed, it will result in an early failure.
And, since all rubbers break down over time from exposure to ozone and weathering, a thinner
cover generally reduces hose life, particularly in tight bend situations.
Fig.43
5.9.3 Spiral reinforced hose
To reach higher system pressures and retain flexibility, wires are applied in four or six spiralled
layers rather than in braids.
Fig.44
5.9.4 Fittings selection
Since hoses vary so much in pressure range, type of reinforcement, and size, there is no “one
coupling fits all” solution. Interchangeable crimp stems can be matched to a ferrule that is ideally
suited to a given hose style. Two-piece fittings also have the advantage of inventory efficiency
and flexibility. In the after-market, one-piece fittings that are designed to be used on the two or
three most popular hose styles provide the most convenient and straightforward solution.
BAI Page 83
a. Two piece fitting b. one piece fitting

Fig.45
 While we are selecting hydraulic hose we might see standard naming (specification) of
the hose: therefore for our clear understanding of their meaning
Fig.46
 In our design we are going to use the working pressure of the fluid to select the hydraulic
hose P=100MPa.The standard selection table we got is in Psi,therefore
99.31bar=1440psi
100bar=X
100.69bar=1460psi
100.69-99.31 = 1460-1440
100-99.31 X-1440
X-1440=0.69*20
1.38
BAI Page 84
X=1450psi….fluid working pressure in psi
 Having this pressure select the hydraulic hose:
Part Hose I.D Hose O.D Rated Min.Burst Min.Bend Wt.perFt.
number (in.) (in.) W.P (psi) radius(in.) (Ibs)
(psi)
A101-08 0.5 0.80 2000 8000 7.0 0.28
A101-10 0.625 0.93 1500 6000 8.0 0.34
A101-12 0.75 1.09 1250 5000 9.5 0.41
Table-14
 From the above table we select part number A101-10 for safer operation of the hose,
having rated working pressure of 1500psi, since our working pressure is 1450psi.
 Type of hose selected-wire braid hydraulic hose, SAE 100R1 Type A NPR 1-wire
braid
 Specifications:
 Inner diameter of hose=0.625in.*2.4cm
=1.5cm
=15mm
 Outer diameter of hose=0.93*2.4
=2.232cm
=22.32mm
 Length of the hose is taken as per the desire of the job(placement of the reservior)
 Recommended for medium hydraulic oil lines
 Tube: Black, oil resistant, Nitrile(NBR.)
 Reinforcement: One braid of higher tensile steel wire
 Cover: Black, oil and abrasion resistant Neoprene(CR)
 Temperature range: -40F to +250F
BAI Page 85
Fig.47 Hose
CHAPTER SIX
6. Over All Benefits Gained From The Internship
Bishoftu Automotive Industry have so many factories and departments together working as one
which enables any one to acquire great knowledge working in each department. In this company
everything from the theoretical design stage up to production and overhauled is done.
6.1. Theoretical knowledge
BAI is a company that applies most of the theoretical teaching that we acquired at university,
like, Machine element, Thermodynamics, Machine design, Hydraulics and Pneumatics. Because
of these facts the company helped us by upgrading our theoretical knowledge on this filled.
In engine and power train production factory we left afew days. Within those times we learned
more things. we saw many types of engines four cylinder up to twelve cylinder engines. From
this we learn by increasing the number of cylinders we can also increases the power of the
BAI Page 86
trucks. Also how it works the mechanism that are used to the transfer of power from the engine
to the hind legs.
we also see sensors that can be used for the smooth functioning of engine. For example
thermocouple (thermostat) is also used to control the temperature of water that is used for
cooling of the engine body. Also a smoke control valve can be used to detect the amount of
smoke that is expelled and increase of the fuel that reaches the cylinder or decrease it.
we also know the use and mechanisms of differential and transfer case. A differential is a device
usually but not necessarily employing gears, cables of transmitting torque and rotation through
three shafts. The purpose of differential is to allow the difference in rotational speed when
turning on curve for the outer and inner wheels.
Transfer case is unique to four wheel drive vehicles and is what directs power to both end
separate axles of the vehicles through two separate drive shafts. Power is directed from the
engine through the transfer case to either the rare wheels or both the rare and the front wheels
Vehicle system production factory, in this shop we learn about the mechanical and electrical
systems that control the different function of vehicles. For example we identified the two types
of injection pumps which are the inline and rotary injection pump. The electrical system which
controls the longitudinal and transverse movements of the turret. These systems incorporate
sensors, amplifiers, hydraulic boosters, etc.
Bus production factory, in this shop we have seen the assembly of every part of the bus like
assembly of hydraulic doors, chassis, leaf springs, tyres etc. And also welding of body, painting
mechanism and paint drying mechanism.
Heavy duty truck production factory, in this shop we have seen the assembly of every
components of styer truck, beiben, sinotruck assemblies like chassis, transmission, engine,
electrical systems.
Automobile production factory, this shop at the time we entered it has stopped production, but
we have seen maintenance of pickups after sell in the shop and there is a big problem in the shop,
while they are maintaining they entered in to a digger hole to maintain the lower part of the
BAI Page 87
automobile like engine. Then we solve this problem by designing a scissor jack, this project is
given to us by the company.
6.2. Practical Skills
In engine and power train production factory, we have gained the practical skills on how to
overhauled vehicles and find problems. Also we have learned the steps that should be taken to
overhaul an engine which are disassembly, inspection, maintenance and assembly. In each step
there are tools that are used specially made for the case and we have familiarized ourselves with
them.
Vehicle system production factory, we have learned different systems of vehicles control the
execution of different outcomes like steering and movement of the turret. we have also learnt
how to recondition different damaged parts like the radiator. The most important knowledge we
acquired in this factory is how to recondition electrical systems and how to integrate them in the
mechanical systems.
6.3. Team Working Skills
BAI has nearly thousands of workers and these workers are appointed a task according to their
personal skills. Dividing the tasks and assigning it into different peopel is more suitable than
everyone trying to do one thing.
The most important part of communication skills is listening and being open minded.
The other main thing in interpersonal skills is the ability to accept criticism. One may see a
problem that other can’t see. It just means that the two persons work together both sees one
problem in different angle. So before some major problems occur, we should be able to accept
criticism and be open minded.
6.4. Leadership Skills
It is the main skill that we acquired in the last internship time. Most of the taskforce at the
industry is technical staff. Only the leader of the taskforce is with some degree. One of the skills
BAI Page 88
to a leadership is to know the task how to do(solve) it.. The other main skill of becoming a leader
is accepting ideas from the task force.
6.5. Work Ethics
Work Ethics and discipline is one of the major factors for the step to professionalism. Issues that
are related to work ethics like punctuality and performance are what make a company to blossom
into greatness or crumple to ashes. The workers in a company should be motivated to work.
CHAPTER SEVEN
7. Conclusion and Recommendation
7.1. Conclusion
To achieve the objective of this project work we have done the design of the single scissor jack
initially. In the design stage, the design calculation of the scissor jack components as well as we
select proper material with consideration of cost and availability. The objective of the project
can be archived by manufacturing the jack.
This machine is mainly designed for solving the problems that affect the production and
maintenance in automobiles production factory. That is by using this machine we can reduce the
crowdedness of the shop, danger to worker and production rate is increased.
BAI Page 89
The machine also avoids backward tools. Because of this the overall flow process and the quality
of the automobile is not affected or it protect parts of the automobile from damaging. Similarly it
decreases loss of time and increases production rate.
It also increases the income of the company by decreasing unnecessary human resource.
This machine is manufacture by easily available materials.
7.2. Recommendation
We recommend the company and any other industries to manufacture the scissor jack in order to
get economical benefits by save foreign currency.
References
1. Joseph Edward shigley,Charles R.Mischke,Mechanical Engineering Design,5th Edition

2. F.Beer,E.Russell Johnson, Mechanics of Materials metric edition.
3. A Text book of machine design, Gupta,5th edition
4. Machine Drawing, K.L. Narayana, P. Kannaiah, K. venkata Reddy
5. Some web sites
BAI Page 90

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Mekelle University 2013

1. History of Bishoftu Automotive Industry

1.1. Objectives Of Project 40720

1.2. Organization Set Up Of Project 40720

1) Operation and Engineering Department

i. Armoured materials overhaul work shop

a) Tank production factory

Fig.1. Tank Fig.2. (BRDM)

Fig.3. Zilla (adma betagn)

b) Engine and power train production factory

I) Bus production factory

1.3. Main Products & Customers

 Production of city Busses, Public transport busses

2. Overall Internship Experience

2.1. Engine & Power Train Production Factory

Engine and power train production factory mainly designed for:-

 Overhaul maintenance and test of engine used in armoured material vehicles

2.1.1. Process Flow of Engine Repair Shop

2.1.2. Process Flow Of Power Supply Units Repair Shop

2.1.3. Work Task In This Shop

i. Layout of the shop

2.2. Construction Machinery Production Factory

2.3. Body & Frame Production Factory

a) New Production Shop

2.3.1. Overall Flow Process Of Producing The Body Of Heavy Trucks

2.3.2. Work Task In This Shop

2.4. Vehicle Production Factory

2.4.1. Overall Flow Process Of Production Of Buses

i. Body & Frame Shop

ii. Painting Shop

iii. Finishing Shop

2.5. Vehicles System Production Factory

2.5.1. Flow Process Of The Shop

(i) Mechanical work group

2. Radiator & Exhaust Manifold

2.6. Measures That Overcome The Above All Challenges

3.1. General objective

The disadvantage of this old system is

- Good working environment

3.5. Applicability of the project

4.2. Definition of scissor lift

4.3. Classification of scissor lifts

4.3.1 Pneumatic scissor lifts

4.3.2. Mechanical scissor lifts

4.3.3. Hydraulic scissor lifts

4.4 Scissor type hydraulic car lift mechanism

4.4.1 Cantilevered platform lift

4.5. HYDRAULIC SYSTEM COMPONANT

2.5.1 Hydraulic pumps

Type Variable Efficiency (%) Pressure range cost

4.5.1A. DOUBLE ACTION HAND PUMPS

4.5.2 HYDRAULIC CYLINDERS

o Double acting cylinder

4.5.3 SELECTOR VALVE

There is a tendency to envision a reservoir as an individual component. In line

4.5.5. HYDRAULIC FLUID

Types of hydraulic fluid basically four used in hydraulic power system

Phosphate ester hydraulic fluid

5.DESIGN OF SINGLE SCISSOR JACK