DESIGN AND FABRICATION OF A GEAR OPERATED TRUCK LIFTING JACK

ABSTRACT


The broad objective of this project was to design and fabricate a gear operated truck lifting
jack that is portable, economically viable, attains simplification, addresses the problems of
the existing jacks and is safe to use.
A survey of vehicle dimensions specifically the wheel diameters and ground clearance
heights was carried to provide a basis of determining dimensions of the jack that would be
suitable for lifting a variety of motor vehicles whose owners would require to use the
designed jack. A spur gear was selected for this project to reduce human effort while turning the handle of the jack.
A static force analysis was done on linkage arms of the jack assembly to determine their
cross-sectional dimensions.
A 3D model of the jack assembly was generated using Solidworks 2016 and subjected to
static stress analysis using its inbuilt software to ensure that the jack assembly does not fail
under the design load. Autodesk Inventor given gear ratio, input torque, gear module and
selected material generated gear profiles that would ensure failure under specified maximum load operating conditions does not occur.
Research findings following Solidworks 2016 analysis showed that the designed spur gear
operated jack is able to lift motor vehicles of up to 2500kg.
In this regard, use of available mild steel in the fabrication of the travelling nuts in place of
phosphor bronze weakened the loading capacity of the jack assembly and for this reason the jack was not subjected to design load tests except confirmation of its lifting mechanism.
Finally a 3D Model Simulation was also developed to give a picture and a realistic animation of its working mechanism.
However it is recommended that further research be done to reduce bulkiness of the jack
assembly by using required high strength materials that would give lesser cross-sectional
dimensions of the linkage members than mild steel used in this project and also ensure that
its loading capacity is achieved.