Professional Documents
Culture Documents
LIFT
CONTENTS
CHAPTER NO
DESCRIPTION
PAGE NO
ABSTRACT
INTRODUCTION
BLOCK DIAGRAM
10
ADVANTAGES
82
11
APPLICATIONS
82
12
CONCLUSION
82
13
BIBLIOGRAPHY
82
SYNOPSIS
The foremost aim of our project is to design and fabricate a hydraulic operated foot
operated Hydraulic lift for the purpose of material handling at a faster rate. At present forklifts,
pallet trucks are used for the purpose of material handling. For forklift it requires a wellexperienced technical person for handling operation. For pallet trucks, it does not have large
cross-section, as the material to be handles is in small unit. For both the equipment the initial
cost is high.
This
project
work
titled
FABRICATION
OF
FOOT
OPERATED
HYDRUALIC LIFT has been conceived having studied the difficulty in lifting and
loading the any type of materials. Our survey in the regard in several small scale
industries, revealed the facts that mostly some difficult methods were adopted in lifting
the material.
Now the project has mainly concentrated on this difficulty, and hence a suitable
device has been designed. Such that the material can be lifted from the floor land without
application of any impact force. The fabrication part of it has been considered with
almost case for its simplicity and economy, such that this can be accommodated as one of
the essential tools on all industries.
INTRODUCTION
This device the hydraulic fork lift has been developed to today itself the needs of small
and medium scale industries, who are normally man powered with very minimum of
skilled labours. In most of the industries the materials are lifted by using high impact man
power and more amount of skilled labours.
In order to avoid all such disadvantages. This, hydraulic fork lift has been designed in
such a way that it can be used to lift the material very smoothly without any impact force. The
operation is made be simple that even an unskilled labour can handled, by just demonstrating the
working of the hydraulic fork lift once.
The hydraulic pump with cylinder arrangement is used to lift the high weighted
material from the ground. This hydraulic fork lift is hand operated one. It is movable
from one place to other place easily by a proper wheel arrangement. Material handling is
a specialized activity for a modern manufacturing concern. It has been estimated that
about 60-70% of the cost production is spent in material handling activities.
HYDRAULIC LIFT
INTRODUCTION : The hydraulic lift is a device used to lift or bring down passengers and
loads from one floor to another in multi-storeyed buildings.
CLASSIFICATION OF HYDRAULIC LIFT
Fixed cylinder: It is fixed with the wall of the floor, where the sliding ram reciprocate
when we apply the pressure.
Cage: It is fitted on the top of the sliding ram where the load is placed (i.e. lifted load).
Sliding ram: It is fitted in the fixed cylinder which is reciprocate (upward or downward
direction) when we applied the pressure (i.e. reaches the floor wise.)
DIAGRAM:
When fluid under pressure is forced into the cylinder, the ram gets a push upward. The platform
carries loads or passengers and moves between the guides. At required height, it can be made to
stay in level with each floor so that the good or passengers can be transferred.
In direct acting hydraulic lift, stroke of the ram is equal to the lift of the cage.
SUSPENDED HYDRAULIC LIFT
CONSTRUCTION DETAILS:
Cage: It is fitted on the top of the sliding ram where the load is placed (i.e. lifted load).
Wire rope: It connects the cage to pulley.
Sliding ram: It is fitted in the fixed cylinder which is reciprocate (upward or downward
direction) when we applied the pressure (i.e. reaches the floor wise)
Pulleys: pulleys are connected to the sliding ram and fixed cylinder; where one pulley is fixed
and other pulley is movable.
Hydraulic jigger: It consists of a moving ram which slides inside a fixed hydraulic cylinder.
Fixed cylinder-: It is fixed with the wall of the floor, where the sliding ram reciprocate when we
apply the pressure.
Working period of the lift is ratio of the height of lift to the velocity of lift.
Idle period of lift is the difference of the total time for one operation and the working period of
the lift.
Introduction:
Earlier, weights were lifted using pulleys, levers, block and tackles, etc. Movements for a ships
rudder or steering a vehicle where achieved by mechanical linkages like cams, levers, couplings,
and gears which made the system complicated. These manual or mechanical methods of
operation had several limitations. They also involved huge man power and long working hours
for a particular job. As the population and technology increased exponentially, the demand for
quicker and easier to operate equipment increased. To cater to this need, hydraulic machines
were introduced.
A simple hydraulic system consists of hydraulic fluid, pistons or rams, cylinders, accumulator or
oil reservoir, a complete working mechanism, and safety devices. These systems are capable of
remotely controlling a wide variety of equipment by transmitting force, carried by the hydraulic
fluid, in a confined medium. Modern developments in hydraulics have involved many fields in
engineering and transportation. These systems transfer high forces rapidly and accurately even in
small pipes of light weight, small size, any shape, and over a long distance. These systems play a
vital role from small car's steering to super sonic aircrafts maneuvering devices. More powerful
and accurate systems are also used in maneuvering huge ships.
ascals Law:
Pascal's Law, framed by Blaise Pascal, states that Pressure applied to any part of a confined
fluid transmits to every other part with no loss. The pressure acts with equal force on all equal
areas of the confining walls and perpendicular to the walls." This is the basic principle for any
hydraulic system.
So, hydraulic pressure can be stated as the force exerted by a fluid on unit area, anywhere on the
surface within the container.
A closed toothpaste tube can be considered as an example for a simple hydraulic system. The
toothpaste can be considered as a hydraulic fluid working inside the system which is confined.
Four or five holes are made on the tube. By keeping the cap of the toothpaste tube closed, apply
pressure at a particular point on the tube. This makes the toothpaste to come out from all the
holes evenly. This is a simple example to understand Pascals law. Thus force applied at a
particular point on a fluid in closed system, transfers equal force on all other parts of the system.
Further, the force acts perpendicular to the walls of the confined area.
Other example is the hydraulic brakes used in automobiles. The driver applies force at the break
pedal (one particular point on fluid in closed system), thus transmitting this force onto the
hydraulic fluid under the piston (break pedal), transfers equal force to all other brake shoes, thus
stopping the vehicle.
There are several other areas where hydraulics are applied. They are:
1. Automobile garage
2. Petrol pumps
3. Measuring weights of heavy-lift trucks
4. Hydraulic cranes
5. Automobile steering gears
6. Automobile brake, (disc brakes)
7. Ship's steering gear
8. Robotics
9. Aircraft's rudder and other maneuvering systems
10. Industries and power plants
11. Servo machanisms and control systems etc.
Also, this same principle is used in hydraulic lifts and other machineries. In the next article we
will discuss how hydraulic presses are used in industries.
Hydraulic cylinder
Operation
Hydraulic cylinders get their power from pressurized hydraulic fluid, which is typically oil. The
hydraulic cylinder consists of a cylinder barrel, in which a piston connected to a piston rod
moves back and forth. The barrel is closed on one end by the cylinder bottom (also called the
cap) and the other end by the cylinder head (also called the gland) where the piston rod comes
out of the cylinder. The piston has sliding rings and seals. The piston divides the inside of the
cylinder into two chambers, the bottom chamber (cap end) and the piston rod side chamber (rod
end / head end).
Flanges, trunnions, clevises, Lugs are common cylinder mounting options. The piston rod also
has mounting attachments to connect the cylinder to the object or machine component that it is
pushing / pulling.
A hydraulic cylinder is the actuator or "motor" side of this system. The "generator" side of the
hydraulic system is the hydraulic pump which brings in a fixed or regulated flow of oil to the
hydraulic cylinder, to move the piston. The piston pushes the oil in the other chamber back to the
reservoir. If we assume that the oil enters from cap end, during extension stroke, and the oil
pressure in the rod end / head end is approximately zero, the force F on the piston rod equals the
pressure P in the cylinder times the piston area A:
During the retraction stroke, if oil is pumped into the head (or gland) at the rod end and the oil
from the cap end flows back to the reservoir without pressure, the fluid pressure in the rod end is
(Pull Force) / (piston area - piston rod area):
where P is the fluid pressure, Fp is the pulling force, Ap is the piston face area and Ar is the rod
cross-section area.
Parts of a hydraulic cylinder
A hydraulic cylinder consists of the following parts:
Cylinder barrel
The main function of cylinder body is to hold cylinder pressure. The cylinder barrel is mostly
made from a seamless tube. The cylinder barrel is ground and/or honed internally with a typical
surface finish of 4 to 16 microinch. Normally hoop stress is calculated to optimize the barrel size.
Cylinder base or cap
The main function of the cap is to enclose the pressure chamber at one end. The cap is connected
to the body by means of welding, threading, bolts, or tie rod. Caps also perform as cylinder
mounting components [cap flange, cap trunnion, cap clevis]. Cap size is determined based on the
bending stress. A static seal / o-ring is used in between cap and barrel (except welded
construction).
Cylinder head
The main function of the head is to enclose the pressure chamber from the other end. The head
contains an integrated rod sealing arrangement or the option to accept a seal gland. The head is
connected to the body by means of threading, bolts, or tie rod. A static seal / o-ring is used in
between head and barrel.
Piston
The main function of the piston is to separate the pressure zones inside the barrel. The piston is
machined with grooves to fit elastomeric or metal seals and bearing elements. These seals can be
single acting or double acting. The difference in pressure between the two sides of the piston
causes the cylinder to extend and retract. The piston is attached with the piston rod by means of
threads, bolts, or nuts to transfer the linear motion.
Piston rod
The piston rod is typically a hard chrome-plated piece of cold-rolled steel which attaches to the
piston and extends from the cylinder through the rod-end head. In double rod-end cylinders, the
actuator has a rod extending from both sides of the piston and out both ends of the barrel. The
piston rod connects the hydraulic actuator to the machine component doing the work. This
connection can be in the form of a machine thread or a mounting attachment....
Seal gland
The cylinder head is fitted with seals to prevent the pressurized oil from leaking past the
interface between the rod and the head. This area is called the seal gland. The advantage of a seal
gland is easy removal and seal replacement. The seal gland contains a primary seal, a secondary
seal / buffer seal, bearing elements, wiper / scraper and static seal. In some cases, especially in
small hydraulic cylinders, the rod gland and the bearing elements are made from a single integral
machined part.
Seals
The seals are considered / designed as per the cylinder working pressure, cylinder speed,
operating temperature, working medium and application. Piston seals are dynamic seals, and
they can be single acting or double acting. Generally speaking, Elastomer seals made from nitrile
rubber, Polyurethane or other materials are best in lower temperature environments, while seals
made of Fluorocarbon Viton are better for higher temperatures. Metallic seals are also available
and commonly use cast iron for the seal material. Rod seals are dynamic seals and generally are
single acting. The compounds of rod seals are nitrile rubber, Polyurethane, or Fluorocarbon
Viton. Wipers / scrapers are used to eliminate contaminants such as moisture, dirt, and dust,
which can cause extensive damage to cylinder walls, rods, seals and other components. The
common compound for wipers is polyurethane. Metallic scrapers are used for sub zero
temperature applications, and applications where foreign materials can deposit on the rod. The
bearing elements / wear bands are used to eliminate metal to metal contact. The wear bands are
designed as per the side load requirements. The primary compounds for wear bands are filled
PTFE, woven fabric reinforced polyester resin and bronze.
Other parts
There are many component parts that make up the internal portion of a hydraulic cylinder. All of
these pieces combine to create a fully functioning component.[2]
Double acting cylinders have a port at each end, supplied with hydraulic fluid for both the
retraction and extension.
applications. Small bore cylinders usually have 4 tie rods, while large bore cylinders may require
as many as 16 or 20 tie rods in order to retain the end caps under the tremendous forces
produced. Tie rod style cylinders can be completely disassembled for service and repair.
The National Fluid Power Association (NFPA) has standardized the dimensions of hydraulic tie
rod cylinders. This enables cylinders from different manufacturers to interchange within the
same mountings.
Welded body cylinder
Welded body cylinders have no tie rods. The barrel is welded directly to the end caps. The ports
are welded to the barrel. The front rod gland is usually threaded into or bolted to the cylinder
barrel. This allows the piston rod assembly and the rod seals to be removed for service.
A Cut Away of a Welded Body Hydraulic Cylinder showing the internal components
Welded body cylinders have a number of advantages over tie rod style cylinders. Welded
cylinders have a narrower body and often a shorter overall length enabling them to fit better into
the tight confines of machinery. Welded cylinders do not suffer from failure due to tie rod stretch
at high pressures and long strokes. The welded design also lends itself to customization. Special
features are easily added to the cylinder body. These may include special ports, custom mounts,
valve manifolds, and so on.
The smooth outer body of welded cylinders also enables the design of multi-stage telescopic
cylinders.
Welded body hydraulic cylinders dominate the mobile hydraulic equipment market such as
construction equipment (excavators, bulldozers, and road graders) and material handling
equipment (forklift trucks, telehandlers, and lift-gates). They are also used in heavy industry such
as cranes, oil rigs, and large off-road vehicles in above-ground mining.
Piston rod construction
The piston rod of an hydraulic cylinder operates both inside and outside the barrel, and
consequently both in and out of the hydraulic fluid and surrounding atmosphere.
Coatings
Wear and corrosion resistant surfaces are desirable on the outer diameter of the piston rod. The
surfaces are often applied using coating techniques such as Chrome (Nickel) Plating, Lunac 2+
duplex, Laser Cladding, PTA welding and Thermal Spraying. These coatings can be finished to
the desirable surface roughness (Ra, Rz) where the seals show optimum performance. All these
coating methods have their specific advantages and disadvantages. It is for this reason that
coating experts play a crucial role in selecting the optimum surface treatment procedure for
protecting Hydraulic Cylinders.
Cylinders are used in different operational conditions and that makes it a challenge to find the
right coating solution. In dredging there might be impact from stones or other parts, in salt water
environments there are extreme corrosion attacks, in off-shore cylinders facing bending and
impact in combination with salt water, and in the steel industry there are high temperatures
involved, etc.... It is important to understand that currently there is no single coating solution
which successfully combats all the specific operational wear conditions. Every single technique
has its own benefits and disadvantages.
Length
Piston rods are generally available in lengths which are cut to suit the application. As the
common rods have a soft or mild steel core, their ends can be welded or machined for a screw
thread.
Hydraulic Cylinder Repair
Hydraulic cylinders form the most integral part of many hydraulic systems. It is a common
practice to dissemble and rebuild an entire device in the case of hydraulic cylinder repair.
Inspection of the leakage issue and scrutinizing cylinder parts (especially the seals) is helpful in
recognizing the exact problem and choosing on the repair options accordingly. Steps involved in
the repair of hydraulic cylinders:
Disassembly of the cylinder parts
First of all, you should place the cylinder in a suitable location, which has sufficient space to
work. If you are working in a cumbersome space, it will be difficult for you to keep track of
opened up parts. After bringing the cylinder to an appropriate spot, open the cylinder ports and
drain out all the hydraulic fluid. The cover of cylinder can be removed by unscrewing the bolts.
Once you take off the cover, remove the piston by loosening the input valves.
Finding out the problem
Once the piston is completely removed, you will be able to see multiple seals on different parts
that are connected to the piston rod. First of all, you need to examine the piston rod to see if there
is any damage. If the shaft of the rod has bends or if the Cylinder Bore has scratches, then get
them repaired at a professional repair shop. If the damage is permanent, then you can order and
manufacture new piston rod for your hydraulic cylinder. Sometimes, piston seals get greatly
damaged, distorted, or broken. Such damaged seals can cause leakage of hydraulic fluid from the
cylinder leading and lower the overall pressure. When such events occur, you know that these
seals need to be replaced.
A hydraulic cylinder without a piston or with a piston without seals is called a plunger cylinder.
A plunger cylinder can only be used as a pushing cylinder; the maximum force is piston rod area
multiplied by pressure. This means that a plunger cylinder in general has a relatively thick piston
rod.
Differential cylinder
Pascals Law
The foundation of modern hydraulics was established when Pascal discovered that pressure in a
fluid acts equally in all directions. This pressure acts at right angles to the containing surfaces. If
some type of pressure gauge, with an exposed face, is placed beneath the surface of a liquid at a
specific depth and pointed in different directions, the pressure will read the same. Thus, we can
say
that pressure in a liquid is independent of direction.
Pressure due to the weight of a liquid, at any level, depends on the depth of the fluid from the
surface. If the exposed face of the pressure gauges are moved closer to the surface of the liquid,
the indicated pressure will be less. When the depth is doubled, the indicated pressure is doubled.
Thus the pressure in a liquid is directly proportional to the depth. Consider a container with
vertical
sides that is 1 foot long and 1 foot wide. Let it be filled with water 1 foot deep, providing 1 cubic
foot
of water. 1 cubic foot of water weighs 62.4 pounds. Using this information and equation, P =
F/A,
we can calculate the pressure on the bottom of the container.
Since there are 144 square inches in 1 square foot, this can be stated as follows: the weight of a
column of water 1 foot high, having a cross-sectional area of 1 square inch, is 0.433 pound. If the
depth of the column is tripled, the weight of the column will be 3 x 0.433, or 1.299 pounds, and
the
pressure at the bottom will be 1.299 lb/in2 (psi), since pressure equals the force divided by the
area.
Thus, the pressure at any depth in a liquid is equal to the weight of the column of liquid at that
depth
divided by the cross-sectional area of the column at that depth. The volume of a liquid that
produces the pressure is referred to as the fluid head of the liquid. The pressure of a liquid due to
its fluid head is also dependent on the density of the liquid.
Gravity
Gravity is one of the four forces of nature. The strength of the gravitational force between two
objects depends on their masses. The more massive the objects are, the stronger the gravitational
attraction.
When you pour water out of a container, the earth's gravity pulls the water towards the ground.
The
same thing happens when you put two buckets of water, with a tube between them, at two
different
heights. You must work to start the flow of water from one bucket to the other, but then gravity
takes
over and the process will continue on its own.
Gravity, applied forces, and atmospheric pressure are static factors that apply equally to fluids at
rest or in motion, while inertia and friction are dynamic factors that apply only to fluids in
motion.
The mathematical sum of gravity, applied force, and atmospheric pressure is the static pressure
obtained at any one point in a fluid at any given time.
Static Pressure
Static pressure exists in addition to any dynamic factors that may also be present at the same
time.
Pascals law states that a pressure set up in a fluid acts equally in all directions and at right angles
to the containing surfaces. This covers the situation only for fluids at rest or practically at rest. It
is
Obviously, when velocity becomes a factor it must have a direction, and as previously explained,
the force related to the velocity must also have a direction, so that Pascals law alone does not
apply to the dynamic factors of fluid power.
The dynamic factors of inertia and friction are related to the static factors. Velocity head and
friction
head are obtained at the expense of static head. However, a portion of the velocity head can
always be reconverted to static head. Force, which can be produced by pressure or head when
dealing with fluids, is necessary to start a body moving if it is at rest, and is present in some form
when the motion of the body is arrested; therefore, whenever a fluid is given velocity, some part
of
its original static head is used to impart this velocity, which then exists as velocity head.
Volume and Velocity of Flow
The volume of a liquid passing a point in a given time is known as its volume of flow or flow
rate.
The volume of flow is usually expressed in gallons per minute (gpm) and is associated with
relative
pressures of the liquid, such as 5 gpm at 40 psi. The velocity of flow or velocity of the fluid is
defined as the average speed at which the fluid moves past a given point. It is usually expressed
in
feet per second (fps) or feet per minute (fpm). Velocity of flow is an important consideration in
sizing
the hydraulic lines.
Volume and velocity of flow are often considered together. With other conditions unalteredthat
is,
with volume of input unchangedthe velocity of flow increases as the cross section or size of
the
pipe decreases, and the velocity of flow decreases as the cross section increases. For example,
the
velocity of flow is slow at wide parts of a stream and rapid at narrow parts, yet the volume of
water
passing each part of the stream is the same.
Bernoulli's Principle
Bernoulli's principle thus says that a rise (fall) in pressure in a flowing fluid must always be
accompanied by a decrease (increase) in the speed, and conversely, if an increase (decrease) in,
the speed of the fluid results in a decrease (increase) in the pressure.
This is at the heart of a number of everyday phenomena. As a very trivial example, Bernoullis
principle is responsible for the fact that a shower curtain gets sucked inwards'' when the water
is first turned on. What happens is that the increased water/air velocity inside the curtain
Backflow
Backflow is the undesirable reversal of flow of nonpotable water or other substances
through a cross-connection and into the piping of a public water system or consumers
potable water system. There are two types of backflow--backpressure and
backsiphonage.
Backsiphonage
Backpressure caused by heat.
Backpressure Examples
Booster pumps, pressure vessels, elevation, heat
Here we see the backpressure of salt water back into the public water system
from a ships pressure pump. Most water providers are now requiring a RP
assembly at the hydrant.
ADVANTAGES:
1.
Hydraulic fork lift develops greater forces than mechanical pressure and hence
it is for forming, bending, and drawing and extrusion operations.
2.
The hydraulic fork lift can exert its full forces at any position of the ram stroke
whereas the force is maximum at the end of stroke in mechanical press.
3.
4.
5.
6.
7.
8.
DISADVANTAGES
1.
2.
APPLICATIONS
1. It is very much useful in all small scale industries.
2. Loading the material from ground level to small vehicle
3. Move weight material to another place
4. Loading and unloading purpose.
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