AT A GLANCE

P: PLANNING BEFORE DOING ANY WORK.

R: RAW MATERIAL REQUIRED FOR THE WORK.

O: ORGANIZATION OF WORK.

J: JOINT EFFORTS PUT TOGETHER IN THE WORK.

E: ESTIMATION OF THE MATERIAL REQUIRED IN THE WORK.

C: COSTING OF WORK.

T: TECHNIQUES USED IN PERFORMING THE WORK

 INDEX
No. Topic Name Page

1. INTRODUCTION

2. CONSTRUCTION

3. WORKING

4. ASSEMBLY DRAWING

5. PROCESS SHEETS

6. COST ESTIMATION.

7. ADVANTAGES & DISADVANTAGES

8. APPLICATION

9. TRIAL & TESTING

10. REFERENCE
CHAPTER ~ 1
INTRODUCTION
 Solar power jack

Introduction:

Former Present president of India Dr.APJ Abdul Kalam, Present President

Mrs. Pratibha Patil and Prime Minister Dr.Manmohan Singh giving the more

intention on developing the renewable energy sources and utilization of the same

in different applications. The domestic, industrial and commercial also.

The main reason to giving pressure on developing the renewable or

nonconventional energy sources is to reduce the fossil fuel cost. The fossil fuels

are like wood, crude oil, natural gases etc. The wood is a very consumable type of

fuel in India hence reducing the jungle and trees. Due to this the pollution is

increased and rains falling also reduced. The another fossil fuels are not fulfilling

the needs of energy of India and the use is very vast in India due to the huge

population. The cost of fuel like crude oil and natural gases are depends on the US

currency hence the prices these fuels are always variable in the world markets we

hear, read and watch the prices of these fuels are increasing day by day .Our

country is big and the use of fuel is also increasing day by day very large part of

economy is spent on fuel in a year. Almost 35% price of total economy of India is

spent on fuel in India which is approximately near to the total price of total

economy spent on the food per year.

Hence as we develops the utilization of natural sources like wind, water and

sunrays. The price spent on fuel is decreased and it can participate the economic

development of India definitely. The machine Power jack which is working on

solar cell.

We are making the material handling equipment that is working on solar.

The main aim is to introduce the use of nonconventional energy source to run the

mechanical machines jack is well known to all for its application & need. It is a

equipment basically used to lift, move, rotate .we know that except some rear cases

any mechanical machines needs some power or drive through any type of

energy.That means external source is needed to work the m/c.As like the jack is

also work on diesel generator engine,electric motor etc.The remaining all parts

remains mechanical including structre,body frame,gear box & all other

accessories.But we are making a new development in our m/c.Instead of motor or

engine,we are using a solar panel & 12v battery.

As the total investment on the project is more we are making the model of

project, but considering the total mechanical design considerations.

CHAPTER ~ 2
CONSTRUCTION
CONSTRUCTION

We are making the design of jack to lift the car up to 10kg.Hence to lift the

weight of 10kg we shall to develop the torque of 10kg. We are designing the

following components .

1)To develop the torque of 10kg to lift the load.

2)Hence design of gearbox to develop the torque.

3)Speed of the final output shaft.

4)Power required to operate the whole assembly & to lift the load.

5)Selection of solar panel to run the motor.

& factor of safety etc.

6) Design of foundation & links where the maximum force acting at Design of

forces acting on the arm of the jack to wistand the load the time of lifting the load.

7) Force or load distribution in the machines due to logical design.

The same design we can use to lift the load up to 1ton taking in consideration the

initial investment & the cost of solar panel.

For max. Capacity of load. We change the values of calculations in the

design & the material to be used. Remaining all format remains the same.

As we get success to drive the jack by solar panel we can implement

the solar panel to develops the another mechanical machineries.

Man has needed and used energy at as increasing rate for his substance and

well. Being ever since be came on the earth a few million years ago. Primitire man

required energy primarily in the form of food. He derived this by eating plants or

animals which he hunted subsequently he discorved fire & his energy need

increased as he started to make use of wood & other biomass to to supply the

energy needs for cooking as well as for keeping himself warm with further demand

for energy man began to use the wind for salling ships & for driving windmills, &

the force of falling water to turn water wheels.Till this time it would not be wrong
to say that the sun is supplying all the energy needs of man either directly or

indirectly & that man was using only renewable sources of energy.

Since 1973,the word “energy” has been continuously in the news. There

have been shortages of oil in many parts of the world & the price of the commodity

has increased sleeply. It is by now clear that the fossil fuel of nonrenewable

resources is gradually coming to an end,oil & natural gas will be depleted first,

followed Eventually by coal.

One of the promising options is to make more extensive use of renewable

sources of energy derived from the sun. Solar energy can be used both directly &

indirectly. It can be use directly in a variety of thermal applications like heating

water or air, drying, distillation & cooking .The heat fluids can return be used for

applications like power generation or refrigeration second way in which solar

energy can be used directly is through (solar cells)the photovoltaic effect in which

it is converted into electrical energy.

Solar energy utilization:

Solar energy is very large inexhaustible source of energy. The power from

the sun intercepted by the earth is approximately 1.81011 mw which is many

thousand of times larger than the present consumption rate on the earth of all

commercial energy sources. Thus in principle solar energy could supply all the
present & future energy needs of the world on a continuing basis. This makes it

one of the most promising of the unconventional energy sources.

In addition to its size, solar energy has two other factors in its favor. Firstly,

unlike fossil fuels & nuclear power, it is an environmentally clean source of

energy. Secondly, it is free & available in adequate quantities in almost all parts of

the world where people live.

The real challenge in utilizing solar energy as an energy alternative is of an

economic nature. One has to striate for the development of cheaper methods of

collection & storage so that the large initial investments required at present in most

applications are reduced.

 Methods of solar energy utilization

Utilization

Direct method indirect method

Thermal Temp. Photovoltaic

Water Wind Bio- Wave Ocean

Power. Power, mass. Energy.
Diff. Equipment’s
The construction of typical liquid flat plate solar collector is shown in figure.

Liquid passage

absorber plates

Transparent covers casing thermal insulation

B) The single crystal silicon cell

The liquid flat plate collector consists of an absorber plate on which the solar

radiation falls after coming through one or more transparent covers (usually made

of glass). The absorbed radiation is partly transferred to a liquid flowing through

tubes, which are fixed to the absorber plate or are integral with it. This energy

transfer is the useful gain. The remaining part of the radiation absorbed in the

absorber plate is lost by convection & re-radiation to the surroundings from the top

surface & by conduction through the back & the edges.

 The transparent covers help in reducing the losses by convection & re-

radiation, while thermal insulation on the back & the edges helps in reducing the

conduction heat loss. The liquid most commonly used is water liquid flat plate

collector is usually held titled in a fixed position on a supporting structure, facing

south if located in the northern hemisphere.

The construction of such a collector is essentially similar to that of a liquid

flat plate collector except for the passages through which the air flows. These

passages have to be made larger in order to keep the pressure drop across the

collector within manageable limits.

The photovoltaic conversion is the another method of solar utilization -

The devices used in photovoltaic conversion are called solar cells when solar

radiation falls on these devices it is converted directly into dc electricity. The

principle advantage associated with solar cells are that they have no moving parts

require little maintenance & work quite satisfactorily with beam or diffuse

radiation. Also they are readily adapted for varying power requirements because a

cell is like a ‘building block’. The main factors limited their use are that they are

still rather costly & that there is very little economy associated with the magnitude

of power generated in an insulation. However significant developments have taken

place in the last few years. New types of cells have been developed innovative

manufacturing processes introduced, conversion efficiencies of existing types

increased costs reduced & the volume of production steadily increased. The

present annual world production of photovoltaic devices is already about

1.5mwp.As a result of the above developments, solar cells are now being used

extensively in many consumer products & appliances,& it is possible that in the

future they may become one of the important sources of power for providing small

amounts of electrical energy for localized use, particularly in remote locations.

CHAPTER ~ 3
WORKING
 Working

BLOCK DIAGRAM:-

Solar DC
Panel Battery

Existing
Screw
Jack
ON-OFF
Gear - 1
Switch

Chain

Gear - 2
DC
Motor
Shop Floor
Motor Shaft

Diagram - Solar Power Jack

Explanation of Components used in Solar Power crane:-

Solar Panel:-

Solar panels are used in order to convert solar energy into dc

voltage. Solar panel is a bunch of number of solar cells. This solar cell absorbs
energy from sun rays and converts into dc voltage. If the strength of sun rays is more
the output voltage is high and it is low when strength is weak.

That is why output from the solar panel is less in the morning
evening and during night hours. And it is maximum at midday. Thus, these solar
panels convert the non conventional energy and thus helping in minimizing the
shortage in conventional energy. This solar energy sources are used for street lights,
laboratory supplies, agricultural farms, solar bikes, water heaters, and house hold
electricity.
These solar panel are available in varies ratings that is 6v, 12v,
18v, 24v, 40v, etc. and different wattages. Say 500 watts, 1000 watts,
2000watts…..etc. In some cases battery chargers are used for charging the battery
but in the applications where the load is not so heavy. The output from solar panel
can be directly connected to the dc battery.
 DC batteries are charged during the day time and store the energy
which is utilized during the hours where there are no sun rays and conventional
electricity is not utilized. DC batteries are available in different ratings. The battery
we utilized in our case is 12v, 10AH capacity.

In the applications where appliances are operating on AC supply,

the battery supply is converted into AC. For this purpose inverters are required. But
in our case the motor used is operated on DC supply. So, there is no need of DC to
AC converter. Also, if the polarity is reversed the motor direction is changed.
DC Motor:-

It is permanent magnet type of DC motor. So, no armature and field winding is there
as in conventional DC motor. Only single supply is required. The motor speed can
be changed if the voltage is changed. But, in our application the motor has to operate
at high torque because, it has lifted the crane. So, gear box is incorporated with the
existing DC motor. This gear box reduces the speed and increases the torque of the
motor.

Mechanical Assembly:-

The mechanical assembly of the project solar power jack consists

of a DC motor with gear attached a chain and another similar gear at opposite end
and which is mounted on a screw jack mechanism. The assembly details are shown
in figure.

It consists of a threaded screw which travels so as to increases

the height of the jack. Hence, it is known as screw jack. The screw jack is used for
lifting the auto cars. One of the flat surfaces of the screw jack is placed on ground
and another flat surface on top side is used to lift the car. Initially the car is on the
ground rested with the helps of wheels. And we require lifting it up for some
purpose. We placed the power jack below the car. Then, with the help of threaded
screw rotation the assembly lifts up which ultimately lifts the car up. Many
accessories like screw, washer, springs… etc. are provided.
 We are about to avoid the human operation for the operation of
power jack. So, the screw jack is expected to rotate automatically when power in
ON. Thus, human power is not require and the battery supply is utilized for the same.
The battery charging is done with solar energy in the system is more beneficial. The
coupling between screw jack and the rotating motor is done with the help of gear
and chain mechanism.
CHAPTER ~ 4
TECHNICAL
SPECIFICATION
Technical Specifications:-

DESIGN OF THE SOLAR POWER JACK

A) Design of gearbox

B) Design of power required developing the torque of 15 kg. = 147.15 N

C) Deign of vertical hanging arm.

D) Design of the foundation.

DESIGN OF VERTICAL HANGING ARM.

1) L = length of the arm – 300 mm.

2) Material of the arm – L – shape angle ==0.75”

3) No. of angles = 2 nos.

4) No. of supporting strips =6 nos.

Dimensions of strips =20mm x 5mm x L

Technical Specifications:-

1) Basic jack = Screw jack, operated manually.

2) Energy source = non conventional from solar panel.
3) DC battery = 12v, 10AH for out applications. It can be increased for
increased capacity.
4) Gear = with 12 teeth on each side. 2 nos.
5) DC motor = 12v, geared.
6) ON-OFF switch = 16 Ampere toggle.
7) Solar Panel = 18 volts, 1000 watt.

B) MACHINE SPECIFICATIONS:-

1) Width of machine – 1100mm X 450mm.

2) Height of machine – 1050 mm.
5) Supply – 12V D.C
6) Motion & motor control limit switch – 0.5 to 1A.
Machine required for completion of above project:-

1) ARC Welding Machine,

2) Drilling Machine,
3) Grinder,
4) leath machine for turning purpose.
5) Electro plating setup.

Parts Lists:-

1) Screw Power Jack = 1

2) Circular Gear = 2
3) Chain = 1 meter
4) DC motor = 1
5) Solar Panel = 1
6) DC battery = 1
7) ON OFF Switch = 1
8) Mounting Fabrication = 1
Cost Estimation of the Project:-

The project, solar crane system is implemented with a proper cost to

performance ratio. Being a development proto, many repetitions are their, which
can not be avoided. Also, each spare of the project is to be done in 01 quantity, so
the costing is more.
Later if the regular production will be started, the costing will be less. The price
details for our development are given as below.

Cost Estimation:-

Material Rates:-
i)Mild Steel = Rs.50/kg
ii)Cast Iron = Rs.50/kg
iii)EN31 = Rs.80/kg
iv)EN8 = Rs.60/kg
v)Gun Metal = Rs.300/kg
Machining Rates :-
i)Turning = Rs.20/hr
ii)Milling = Rs.40/hr
iii)Drilling = Rs.15/hr
iv)Shaping = Rs.20/hr
v)Horizontal Boring = Rs.150/hr
vi)Surface Grinding = Rs.75/hr
vii)Ram Milling = Rs.50/hr
viii)Hardening = Rs.30/kg
ix)Toughening = Rs30/kg
x)Cylindrical Grinding = Rs.75/hr

 Component wise Details:-

1.Vice Base:-
Material=C.I.
Weight=20Kg
Material Cost=20x50=1000Rs.
Machining Cost =Shaping+Grinding+Milling
=80+750+40=870Rs.
Total cost=1000+870=1870Rs.

2.LH/RH Screw:-
Material=EN8
Weight=6Kg
Material Cost=6x60=360Rs.
Machining Cost=Lathe+Milling
=90+45=135Rs.
Total Cost=495Rs.

3.Gun Metal Nuts:-

Material=G.M.
Weight=3Kg
Material Cost=3×300=900Rs.
Machining Cost=Lathe+Drilling
=55+5=60Rs.
Total Cost=960Rs.
4. Clamp:-

Material=M.S.
Weight=1Kg
Material Cost=1×50=50Rs.
Machining Cost=Lathe+Milling+Drilling
=15+10+5=30Rs.
Total Cost=80Rs.
5. Rest Pad:-

Material=M.S.
Weight=0. 5Kg
Material Cost=0.5×50=25Rs.
Machining Cost=Milling+Drilling+Shaping
=20+5+10=35Rs.
Total Cost=60Rs.
6.solar panel
1x4000
= 4000
Machining Cost=Welding+Drilling
=5+10=15Rs.
Total Cost =4015Rs.

7. Battery

=2000x1
=2000Rs.
Total Cost =2000Rs.

8.moter
1x1500
= 1500
Machining Cost=Lathe+Plumbing+Drilling
=20+5+10=35Rs.
Total Cost =1535Rs.

9. Gear
4 x700
= 2800
Machining Cost=Lathe+Plumbing+Drilling
=20+5+10=35Rs.
Total Cost =2835Rs.
10 . chain
1 x180
= 180
Machining Cost=Lathe+Plumbing+Drilling
=20+5+10=35Rs.
Total Cost =215Rs

11 switch
1 x150
= 150
Machining Cost=Drilling
=10=10Rs.
Total Cost =165Rs

Total cost RS. =14035

 CHAPTER NO.

Time Study of Operations:-

1 Project Selection 95 Days

2 Literature Survey 15 Days
3 Title Finalization 15 Days
4 Selection of solar panels 2 day
5 Selection of battery 15 Days
6 Selection of switch 5 Days
7 Selection of gear 10Days
8 Selection of motor 02 Days
9 Selection of shaft 02 Days
10 Selection of chain 02 Days
11 Purchase of solar panel 1 day
12 Purchase of battery 10 day
13 Purchase of motor 03 day
14 Purchase of switch 01day
15 Assembly of Component 10 Days
16 Mechanical Trials 25 Days
17 Taking the joint trials of mechanical system 02 Days
18 Achieving the results 05 Days
19 Documentations for results 10 Days
CHAPTER ~ 7
ADVANTAGES &
DISADVANTAGES
Advantages:-

1) Being the jack operated on DC supply and dc supply is obtained form solar
energy. It helps in minimizing the shortage of conventional energy. Also,
the battery can be charged during the traveling of the car.
2) The operation is done, by closing a single switch which helps in avoiding
the man power, for jack operation.
3) Being DC motor is suggested NO inversion of DC supply is required.

Disadvantage:-

1) Solar panel is can not be charge in rainy season. So, these systems are
helpless in rainy season.
Future Scope:-

1) The solar based power jacks so developed have many advantages steel
some lacunas are there. These lacunas are over come in further
enhancement circuitry project.
2) In rainy season the conventional electricity generation is more, so, the
battery charging can be done without solar. For this purpose the required
battery charges will be developed in futures.
3) In future enhancements the power required for lifting the car will also,
measured by using some transistors and if the load is more than the
recommended load of the jack, the system will be stopped.
4) On line charging can be done.
 CHAPTER NO.

MAINTENANCE OF THE MACHINE

1) PREVENTIVE MAINTENANCE:-

a) Add lubricant inside the gear box timely to reduce friction & wear.

b) Charge battery regularly.

c) Do not attach weight more than specified in safe design.

d) Supply should be connected properly.

2) BREAKDOWN MAINTENANCE:-

a) Replace battery in case of short circuit.

b) Replace gear in case it is wearied.

c) Replacement of rope if it is broke down.

d) Replacement of bearings after finishing of its life cycle.