©Copyright by ……MBINGFEPOH IVAN MBOZIKEH…….

, year of submission

All rights reserved

DECLARATION OF ORIGINALITY OF STUDY
I, MBINGFEPOH IVAN MBOZIKEH, registration N0 : UBa18E0099, in the Department of
Mechanical and Industrial Engineering, National Higher Polytechnic Institute, The University of
Bamenda hereby declare that this work titled “DESIGN AND REALIZATION OF AN
ELECTRIC CAR JACK FOR LIGHT VEHICLES” is my original work. It has not been
presented in any application for a degree or any academic pursuit elsewhere. I have
acknowledged all borrowed ideas nationally and internationally through citations.

Date: ___________________ Signature of author ________________

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CERTIFICATION
This is to certify that this project titled “DESIGN AND REALIZATION OF AN ELECTRIC
CAR JACK FOR LIGHT VEHICLES” is the original work of MBINGFEPOH IVAN
MBOZIKEH. This work is submitted in partial fulfillment of the requirements for the award of
a Bachelor of Engineering Degree in Mechanical and Industrial Engineering in the National
Higher Polytechnic Institute of The University of Bamenda, Cameroon.

Supervisor : ______________________________________________________
Prof. DJAFANG DESIREE

The Head of Department : __________________________________________

Mr. BECHING ROLAND ORU

The Director : ____________________________________________________

Prof. FIDELIS CHO NGWA

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ABSTRACT

iii
RESUME

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DEDICATION
To my most cherished family

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ACKNOWLEDGEMENT

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table of contents

vii
List Of Tables

viii
List Of Figures

ix
List Of Abbreviations

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 CHAPTER ONE

INTRODUCTION
1.1 Background of the study
Doing work in a bent or squatting position for a period of time is not ergonomic to human
body. An automotive jack is a device used to raise all or part of a vehicle mainly for
maintenance purposes. In the society today, there are numerous types of jacks available for
use to people. There is the more popular scissor screw jack (manually operated) most
common in the north west region which comes with their vehicles. Nowadays, a variety of
car jacks have been developed for lifting an automobile from a ground surface. Available car
jacks, however, are typically manually operated and therefore require substantial laborious
physical effort on the part of the user. Such jacks present difficulties for the elderly and
handicapped and are especially disadvantageous under bad weather conditions.
In light of such inherent disadvantages, commercial automobile repair and service stations
are commonly equipped with large and hi-tech car lift, wherein such lifts are raised and
lowered via electrically-powered systems. However, due to their size and high costs of
purchasing and maintaining electrically-powered car lifts, such lifts are not available to the
average car owner.
1.1.1 Historical background of the jack
The virtues of using a screw as a machine, essentially an inclined plane wound round a cylinder,
was first demonstrated by Archimedes in 200BC with his device used for pumping water. There
is evidence of the use of screws in the Ancient Roman world but it was the great Leonardo da
Vinci, in the late 1400s, who first demonstrated the use of a screw jack for lifting loads.
Leonardo’s design used a threaded worm gear, supported on bearings, that rotated by the turning
of a worm shaft to drive a lifting screw to move the load - instantly recognizable as the principle
we use today. We can’t be sure of the intended application of his invention, but it seems to have
been relegated to the history books, along with the helicopter and tank, for almost four centuries.
It is not until the late 1800s that we have evidence of the product being developed further. With
the industrial revolution of the late 18th and 19th centuries came the first use of screws in
machine tools, via English inventors such as John Wilkinson and Henry Maudsley The most
notable inventor in mechanical engineering from the early 1800s was undoubtedly the
mechanical genius Joseph Whitworth, who recognized the need for precision had become as
important in industry as the provision of power. A screw jack that has a built-in motor is now
referred to as a linear actuator but is essentially still a screw jack. Whitworth’s have become
internationally famous for their precision and quality, and dominated the market from the
1850th. Inspired young engineers began to put whit worth’s machine tools to new uses. During
the early 1880th in Coati cook, a small town near Quebec, a 24-year-old inventor named Frank
Henry Sleeper designed a lifting jack. Like da Vinci’s jack, it was a technological innovation
because it was based on the principle of the ball bearing for supporting a load and transferred
rotary motion, through gearing and screw, in to linear motion for moving the load. The device

1
was efficient, reliable and easy to operate. It was used in the construction of bridges, but mostly
by the rail road industry, where it was able to lift locomotives and railway cars.
1.2 Statement of the problem
The modern-day jacks existing have solved most of the users problems though they still have
some limitations. This project is aimed at eliminating these limitations.
This project first solves the problem of stress. Most existing jacks readily available to users
are manually operated. This implies much human effort is needed to lift the vehicle using the
jack. Even the hydraulic jacks in existence still require human effort to operate. With the
electric screw jack, this manual effort is replaced with the motor thus making this an easy
task.
Also, this project is an easy to use system implying it is accessible to the elderly and
handicapped which is also time saving compared to the existing jacks which cannot be
operated by the elderly and handicapped and are also time consuming.
1.3 Rationale
Vehicle jacking is a very important factor in the automobile industry. Most car maintenance
workshops need a suitable jack to carry out maintenance such as changing of engine oil,
maintenance of the exhaust pot, replacement of brakes etc. Jacking is equally important to all
vehicle owners. Having a punctured tire in a secluded area or when in a haste can be really
frustrating because of the stress involved in changing the tire. It has also been noted that the
roadside assistance to come and assist, is not readily available in the remote rural roads of the
country.
Over the years, numerous jacks have been brought into existence. Currently, there are 3
major jacks in existence i.e. Screw jack(bottle screw jack and scissor screw jack), Hydraulic
jack(bottle hydraulic jack and floor jack), and finally the hi-tech car lifting system where
vehicles are raised and lowered using an electrically powered system present only in
automobile maintenance shops due to their high cost and size.
It can be seen from the examples above that these jacks are all manually operated (they
require substantial human effort in order to function meaning the elderly and handicapped
can not use them. Also, the fact that is manual implies it is time consuming. This study seeks
to eliminate all these limitations as it is a fast, easy to use system.
1.4 Research questions
The following research questions would have to be properly examined in order to realize this
project:
i. How is carjacking carried out?
ii. What are the constraints involved in the current jacks?
iii. How can these constraints be resolved for easier modelling and design?
iv. What are the ongoing researches for better jacks in the future?

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1.5 Objectives
1.5.1 Overall Objective
The overall objective of the present study is to design and realize an electric jack for light
vehicles.
1.5.2 Specific Objectives
The specific objectives are:
i. To conserve energy and save time through the use of electric car jack.
ii. Create a design of the electric jack using Solidworks 2018
iii. Realize the electric jack
1.6 Scope And Delimitation
1.6.1 Scope
This research aims at providing an easy to use way of jacking vehicles for the elderly and
handicapped persons. The design is portable and the mechanism is easy making maintenance
easy. This research will be based in the north west region of Cameroon and will run for a period
of 4months.
1.6.2 Delimitation

1.7 Definition Of Terms

1.8 Overview Of Dissertation

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 CHAPTER TWO

LITERATURE REVIEW
2.1 Car Jack
A jack is mechanical device used to lift heavy loads or apply great forces. Jacks employ a
screw thread or hydraulic cylinder to apply very high linear forces. A mechanical jack is a device
which lifts heavy equipment more powerful jacks use hydraulic power to provide more lift over
greater distance. The mechanical advantage is the factor by which a mechanism multiplies the
force or torque applied to it.
2.1.1 Types of Jacks
Vehicle jacks are broadly classified into 2 major categories based on their principle of operation
namely Mechanical and Hydraulic jacks;
2.1.1.1 Mechanical Jacks
Jacks that fall under this category use purely mechanical methods of creating lift.
This may mean using a screw to raise and lower a hinged mechanism incrementally or using a
ratcheting system to lift a vehicle a notch at a time slowly. Included in this category are your
basic scissor jack, the high lift jack.
2.1.1.1.1 Screw Jack
A device which uses a high mechanical advantage that may be operated by using either:
(a) Rotating the screw when the nut is fixed; or
(b) Rotating the nut and preventing rotation of the screw.
Bottle jacks mainly consist of a screw, a nut, thrust bearings, and a body. A stationary platform is
attached to the top of the screw. This platform acts as a support for the load and also assists it in
lifting or lowering of the load. These jacks are sturdier than the scissor jacks and can lift heavier
loads

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Bottle Screw Jack (source: Amazon.ae)

Advantages
 Easy to operate
 Portable
 Self locking jack.
Disadvantages
 Screw jacks are limited in their lifting capacity.
 Maunually operated implying stressful.
 Increasing load increases friction within the screw threads thus reducing lifespan of jack.
2.1.1.1.2 House Jacks
These heavy-duty screw jacks are used to raise and stabilize buildings or heavy beams in
construction applications, such as relocation or repairs. Wood cribbing supports the structure
until the house jacks successfully lift the load to its desired height.

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House Screw Jack (source: Walmart.com)
2.1.1.1.3 Scissor Jacks
Mechanical scissor jacks are most common today and have been in use at least since the 1930s.
Because scissor jacks are compact, they can be stored and transported easily in the trunk of the
car. A scissor jack is a device constructed with a cross-hatch mechanism, much like a scissor, to
lift up a vehicle for repair or storage. A scissor jack is a device which is used to lift heavy
vehicles, partially or fully in the air for breakdown and maintenance. Scissor jack includes one
power screw which is rotating, two fixed nuts, four links which is connected to nuts, eight pins
used to fixed that four links, two rings provided at screw end and load platform supported by
upper two links.
Working Principle
As the screw section is turned, two ends of the jack move closer together. Because the gears of
the screw are pushing up the arms, the amount of force being applied is multiplied. It takes a
very small amount of force to turn the crank handle, yet that action causes the brace arms to slide
across and together. As this happens the arms extend upward. The car's gravitational weight is
not enough to prevent the jack from opening or to stop the screw from turning, since it is not
applying force.
Disadvantages
 relatively slow to operate
 light weight and cant be used for heavy vehicles
 require lots of human effort in order to lift load
 high friction causes rapid wear of thread.

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 Scissor Screw Jack (source: jumia.com)

2.1.1.2 Hydraulic jacks

A hydraulic jack is a mechanical lifting device used to lift heavy loads or to apply great forces. A
hydraulic jack uses a liquid, which is incompressible, that is forced into a cylinder by a pump
plunger. Oil is used since it is self-lubricating and stable. When the plunger pulls back, it draws
oil out of the reservoir through a suction check valve into the pump chamber. When the plunger
moves forward, it pushes the oil through a discharge check valve into the cylinder. The suction
valve ball is within the chamber and opens with each draw of the plunger. The discharge valve
ball is outside the chamber and opens when the oil is pushed into the cylinder. At this point the
suction ball within the chamber is forced shut and oil pressure builds in the cylinder.
How do hydraulics work? Without going too deep into the physics, basically a hydraulic system
takes advantage of the fact it is really difficult to compress a fluid. Hydraulic jack is based on the
Pascal’s law which states that increase in pressure on the surface of a confined fluid is
transmitted undiminished throughout the confined vessel or system.

The jack has a reservoir full of a sort of oil. On the upstroke of the handle, some of that oil is
pulled from the reservoir. On the downstroke, that portion of the oil is forced into the central
cylinder and underneath a piston. As the amount of fluid under the piston increases, the pressure
(which keeps building because the oil won’t compress) pushes the cylinder up. It will stay up
until the oil is let out and flows back into the reservoir.
2.1.1.2.1 Bottle Jack
Bottle Jacks became popular in the early 1900s when the automobile industry began to take off.
Also called hand jacks, bottle jacks provided an easy way for an individual to lift up a vehicle for
7
roadside inspection or service. Their resemblance to milk bottles earned bottle jacks their name
today, they range in size and weight to offer a lifting capability ranging from one hundred to
several tons. Bottle jacks feature a vertical shaft, which supports a platform (called a bearing
pad) that directly bears the weight of the object as it is lifted. Although they are most commonly
used in the automobile industry (1.5 to 5 ton jacks are frequently used to lift cars), bottle jacks
have other uses as well. Their ability to lift heavy loads plays a big role in enabling the repair of
large agricultural machinery and in many construction operations. Bottle jacks can be secured
within a frame, mounted on a beam, or simply used as they are for easier jack transportation.

3-ton bottle hydraulic jack

2.1.1.2.2 Floor jack

Unlike bottle jack shafts, the shaft in a floor jacks is horizontal—the shaft pushes on a crank that
connects to a lifting pad, which is then lifted horizontally. Floor jacks typically provide a greater
range of vertical lift than bottle jacks, and are available in two sizes. The original jack is about
four feet long, a foot wide, and weights around 200 pounds—they can lift 4-10 tons. A more
compact model was later made, which is about three feet in length, and can lift 11/2 tons.
Although mini jack are also produced, they are not a recognized standard type of floor jack.
Typically, one of the first two sizes should be used.

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A floor jack (source: hydraulic suspension.com)

2.1.1.2.3 Pneumatic Jack

It’s a hydraulic jack that functions with the assistance of compressed gas. This sort of hydraulic
jack could be a telescopic jack that is ideal for buses, trucks, and significant duty machinery. It
provides simple and quick lifting. This jack is meant to perform for very high axles and operates
swimmingly and taciturnly on the ground. It’s 3 handle point choices that modify simple
maneuver450

A pneumatic jack (source: hydraulic suspension.com)

Working principle of Hydraulic Jack

Hydraulic jack works on the principle of ―Pascal‘s law. When the handle is operated, the
plunger reciprocates then the oil from the reservoir is sucked into the plunger cylinder during
upward stroke of the plunger through the suction valve. The oil in the plunger cylinder is
delivered into the ram cylinder during the downward stroke of the plunger through the delivery
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valve. This pressurized oil lifts the load up, which is placed on top plate of the ram. After the
work is completed the pressure in the ram cylinder is released by unscrewing the lowering screw
thus the pressure releases and the ram is lowered, then the oil is rushed into the reservoir. It
consists of plunger cylinder on one side and ram cylinder on the other side. These two cylinders
are mounted on base which is made of mild steel. Plunger cylinder consists of plunger which is
used to build up the pressure by operating the handle. Plunger cylinder consists of two non-return
valves i.e. one for suction and other for delivery. Ram cylinder consists of ram which lifts the
load. The ram cylinder connected to delivery valve of plunger cylinder. It is also consists of
lowering screw this is nothing but a hand operated valve used for releasing the pressure in the
ram cylinder for get down the load. The hydraulic jack uses a piston pump.

2.1.1.2.4 Strand Jack

This jack is employed for lifting significant construction loads and for engineering procedures.
It’s used worldwide to strengthen offshore structures, bridges, power stations, refineries, and
different structures. A strand jack is employed for sliding operations and work procedures.

A strand jack (source: hydraulic suspension.com)

Disadvantages of Hydraulic jack

Below are some disadvantages of Hydraulic Jack.

 It is at risk of failure if the oil seals are exhausted, this will cause serious issues
 It has a comparatively slow speed

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  Hydraulic oil will emit an unpleasant odor once become too heat thanks to overuse
 It will overheat fairly fast
 Hydraulic oil leak will cause soil

2.2 Electric Motor

An Electrical Motor is a machine that converts electrical energy into mechanical energy. It is
used for generating torque to lift loads, move objects & various other mechanical work. In the
following article, we will discuss the different types of electric motors such as AC, DC and
special types of motors etc
2.2.1 AC Motors
The AC electric motor converts AC (Alternating Current) electrical energy into mechanical
energy. These electric motors are powered using a single-phase or three-phase alternating
current. The basic working principle of AC motor is the rotating magnetic field (RMF) generated
by the stator winding when an alternating current is passed through it. The rotor (having its own
magnetic field) follows the RMF & starts rotation.
AC motors are further classified into two types, i.e. synchronous and asynchronous
2.2.1.1 Synchronous Motor
As its name suggests, such AC motor has a constant speed called synchronous speed that only
depends on the frequency of the supply current. The speed of such electric motors only varies
with variation in supply frequency & remains constant upon varying loads. It is used for constant
speed application & precision control.
2.2.1.2 Asynchronous Motor
The type of AC motor that never runs at synchronous speed is called asynchronous speed. Its
rotor speed is always less than the synchronous speed. It does not require separate rotor
excitation.
The asynchronous motors are briefly classified into two types;
 Induction Motor
 Commutator Motor
Induction Motor
The induction motor is a type of AC asynchronous motor that works on the principle of
electromagnetic induction between the stator & the rotor. The revolving magnetic flux induces a
current in the rotor due to electromagnetic induction which produces torque in the rotor. It is the
most used electrical motor in industries.

Commutator Motor

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This is a type of AC motor that utilizes commutator & brush assembly to supply power to its
rotor. Such electric motors have wound-type rotor.
2.2.2 DC Motor
The DC motor is another main type of electrical motor that only runs on DC or Direct Current.
There are no phases in direct current that is why DC electric motors only uses 2 wires to run.
They are the first motors to be invented. It is easier to control its speed by only varying the
supply voltage. It offers simple starting, stopping, accelerating & reversing mechanisms. The
installation cost of DC motor is very cheap but they do require maintenance whose cost increases
significantly with increasing the size & power of the motor. 
The basic working principle of DC motors is the Fleming’s left hand rule. A current carrying
conductor inside a magnetic field experience a force of thrust mutually perpendicular to each
other.
The DC motors can be briefly classified into following types
 Brushed DC Motor
 Brushless DC Motor
 Coreless or Ironless DC Motors
2.2.2.1 Brushed DC Motor
As the name suggests, such DC electric motors have brushes & commutators. They are used for
connecting a stationary circuit with a rotating circuit. In such case, the rotor winding of the motor
is energized through conductive brushes. The disadvantage of any brushed motor is that they
require frequent maintenance due to continuous sliding of brushes & the sparks generated
between them. However, they are quite simple in design & are in expensive.
2.2.2.2 Brushless DC Motor
As the name suggests, Brushless or BLDC Motor is an another main type of DC motor that does
not have any carbon brushes & commutators assembly. It means the input power is not supplied
to the rotating part of the motor but to the stator of the motor which in this case is made of
multiple windings & the rotor is made of a permanent magnet.
2.2.2.3 Coreless or Ironless DC Motors
As the name suggests, such DC motors have no laminated iron core. The rotor winding is wound
in skewed or honeycomb shape to form a self-supporting hollow cage often made with using
epoxy. The rotor made of permanent magnet sets in the hollow rotor.
The coreless design eliminates the issues & losses associated with the iron cores of the
traditional motors. For example, such electric motors have no iron losses which increases the
efficiency of the motor up to 90%. The design also reduces the winding inductance which
reduces the sparks generated between the brushes & commutator thus increasing the lifetime of
the motor. It also reduces the mass & inertia of the rotor which also increases the acceleration &
deceleration rate of the motor.

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2.2.3 Special Motors
There are several types of special electric motors that are the modified versions of other motor
designed for special purposes. Some of these electric motors are given below.
2.2.3.1 Servo Motors
Servo motor is a special type of motor used for pushing/Pulling or lifting or rotating an object at
some specific angle. Servo motor can be designed to run on AC as well as DC power supply.
Servo motor that runs on DC supply is called DC servo motor While those that runs on AC is
called AC servo motor. It is a simple motor with a controller & multiple gears to increase its
torque.
2.2.3.2 Direct Drive
Direct drive motor or also known as torque motor is another type of motor that produces high
torque at low speed even when it is stalling. The payload is directly connected to the rotor thus
eliminating the use of gearbox, belts, speed reducers etc. It is a brushless permanent magnet
synchronous motor with no commutators & brushes. Since there is no mechanical wear & tear, it
reliable & has a long lifetime. The fact that it has less mechanical parts means it require less
maintenance and low cost.
2.2.3.3 Stepper Motor
A stepper motor or a stepping motor is a brushless DC motor whose full rotation is divided into a
number of equal steps. Such motor rotates in steps (fixed degrees) instead of rotating
continuously. Such stepping movement offers great precision which is utilized is robotics.
The stepper motor operates on pulses. Each pulse moves the motor by one step. The precision of
the motor depends on the number of steps per revolution. The steps size is determined during its
design. However, the speed of the motor can be controlled by applying the pulse train of variable
frequency. The controller inside the servo motor moves forward or backward the rotor by one
step upon each pulse.
It is used for its accurate & precise positioning. It offers full torque at standstill. It has less
maintenance requirement due to brushless design. Thus they are very reliable & has long
lifetime.
Stepper motor due to its precise positioning is used in industrial machines used for automatic
manufacturing of products, CNC based machines. It also found applications in medical
instruments & machinery as wells as in security cameras. Stepper is widely used in electronic
gadgets & other smart electronic systems.
2.2.3.4 Universal Motor
The Universal motor is a special type of motor that can run on AC as well DC power supply. it is
a brushed series wound motor where the field windings is connected in series with the armature
windings. They offer maximum starting torque with a high operating speed.

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Since the windings are connected in series, the direction of the current through both windings
remains the same even if the current direction reverses multiple times in a second. Although, the
motor may run slower on AC due to the reactance of the windings.
2.3 Research on Previous work carried out
Author Timur Choban Khidir says in his research paper (Design and Manufacturing Electrical
Bottle Car Jack D.C. 12 volt) that the tire puncture problem of the cars on the roads, especially
on the highway roads generally needs manual human force to solve the problem by using a
mechanical scissor car jack. Our work focused on a bottle carjack and adapting D.C. motor (12
volts) with chain-sprocket set to design a suitable machine. Lifting the car to solve the puncture
problem with this new machine is easier, safer, abbreviate the time and more reliable for persons
who suffer from their health’s. We used drilling, grinding, milling, and welding machines to
make up this work. The designed jack had been tested on a passenger car and passed
successfully. We used Solidworks software program to achieve the goal. In the conclusion, the
main physical parameters of the design with reasonable assumptions have been determined
through practical considerations. Cast alloy is used as the materials for both chains due to its
high strength, toughness, and its economic effects and cast carbon steel used in Jack. Depending
on the analysis of FEA, it shows that the max. Nodal displacement value of the system of carjack
is about 1.048e-001 mm and max. Von Mises 3.625e+008, when max. load (19620 N) applied
Furthermore, it seen that max. Von Mises stress, max. safe point. And we tried this carjack on
the vehicle (Kia Rio model 2005 its curb weight is 1090 kg) practically to see whether it raise the
vehicle or not.
The limitations of his system was that
 The production cost of chains is relatively high.
 The chain drive needs accurate mounting and careful maintenance, particularly
lubrication and slack
 adjustment.
 The chain drive has velocity fluctuations especially when unduly stretched.
 Need lubrication and therefore can be messy.

Author Manoj Patil, Gaurav Udgirkar, Rajesh Patil and Nilesh says in his research paper
(Automated Car Jack) that an automotive jack is a device used to raise all or part of a vehicle

14
into the air in order to facilitate repairs. Most people are familiar with the basic car jack
(manually operated) that is still included as standard equipment with most new cars. These days,
a car jack is an important tool to have in our vehicle due to unknown upcoming event such as flat
tire in our journey. Even so, people who like to rotate their tires themselves or who may install
snow tires before the winter and remove them in the spring need to use a jack to perform the job.
Changing a flat tire is not a very pleasant experience. Women have a much lighter skeleton that
men, among other things, women can’t pull more forces as well as men and are at greater risk of
skeletal injuries. Usually the car purposely tries to get a flat tire at the least opportune moments.
On average, 160 injuries are associated with car jacks each year. Injuries have ranged from
amputation to fractures and crush injuries. The correct use of jacks can prevent death or injury.
Improvement in automotive car jack is really needed to make the tool more efficient, user-
friendly, practical to use, changes in industry direction and most importantly high safety features.
Further research on car jack is very important.
Operating the manual car jack is quite difficult job for pregnant women and old men. The
purpose of this project is to encounter these problems. An electric car jack works on current
supply from the car battery itself making it easy to operate. Operator only needs to press the
button from the controller without working in a bent or squatting position for a long period of
time to change the tire. In order to fulfil the needs of present car jack, some improvement must
be made. And they concludes that the main advantages of the modified design over the existing
design are that the modified designed motorised jack will save time, be faster and easier to
operate and requires less human energy and additional work to operate. There by effectively curb
the problems associated with Ergonomics - which is a fundamental concept of design process.
Considering all available car jacks in the market, this prototype can be improved by a few
modifications on the features and design. The objectives are to design a car jack that is safe,
reliable and able to raise and lower the level, to develop a car jack that is powered by internal car
power and automated with button system. Based on the testing and results from the analysis, it is
considered safe to use Jack car work under certain specifications. Furthermore the torque
supplied on the system is more than enough to lift a car weight around 1200 kg. There are certain
weak points that can be improved based design and balancing of the system.

Author A. S. Akinwonmi and A. Mohammed says in his research paper (Modification of the
Existing Design of a Car Jack) that modification of the existing motor screw jack by

15
incorporating an electric motor in the screw in order to make load lifting easier. In this modified
design, the power screw is rotated through its connecting gear with the pinion gear when
electrical power flows through the cigarette lighter receptacle connected to the motor, plugged to
the automobile 12 V battery source to generate power for the prime mover (motor), which
transmits its rotating speed to the pinion gear meshing with the bigger gear connected to the
power screw to be rotated with required speed reduction and increased torque to drive the power
screw. The significance and purpose of this work is to modify the existing car jack in order to
make the operation easier, safer and more reliable in order to reduce health risks especially back
ache problems associated with doing work in a bent or squatting position for a long period of
time. The modified car jack is easy to use by pregnant women or whoever had problem with the
vehicle tyres along the road. The designed motorised jack will also save time and requires less
human energy to operate. The design when adopted will effectively curb the problems associated
with Ergonomics - which is a fundamental concept of design process. And they concludes that
The limitation of this design is that it is only applicable to vehicles not weighing above 1000 kg.

Author C.S. Dhamak et al researched on design, optimize and standardize the current toggle
jack to make the task easier and reliable and to avoid field failure. They mainly focused on
designing and standardization of scissor jack model of automobile L.M.V. sector and trying for
weight reduction of scissor jack with good strength. They conclude that for safe design of screw
and nut a bearing pressure need to be considered and if we take combination of different material
for each pair of crew and nut so we can find best suitable material for design at maximum load.
Author Shashikant A. Pekhale and Prof. S. V. Karanjkar works on modification and analysis
of the current mechanical scissor jack by incorporating an electric DC motor in the screw in
order to make load lifting easier for lifting motor vehicles with using power of car battery (12
Volts).they conclude that The existing jack was modified by making small alteration and making
use of an electric motor to drive power screw, connecting gear with the pinion mounted on the
motor shaft and then it will save time, be faster and easier to operate and requires less human
energy and additional work to operate.
Author Chetan S.Dhamak et al presented their research on designing and optimization of
mechanical scissor jack at the same time maintaining its strength and service life. After they

16
study failure modes made a mathematical model analytically and by using ANSYS software.
They concluded that scissor jack is failed due to wear of teeth on both links at lower end, Due to
excessive use and high impact on screw starts getting wear and head of jack starts bending due to
the fatigue load acting continuously again & again over the head.
Author Alexander et al, 1978, Smith, 1981, Nelkon, 1985 ). A lifting device is a system that
allows small force (effort) to overcome a large force or load There are practically hundreds of
uses for lift tables in manufacturing, warehousing and distribution facilities. The Addition of this
device (lift table) makes job faster, safer and easier. Some typical Applications include; machine
feeding and off-loading, product assembly, inspection quality control repair, feeding and
offloading conveyor levels. The commonest method for operating a scissors lift is the use of a
power screw. We can see that from the above literature review that we can make our design
easier by using electric motor to rotate the power screw in order to make lifting easier, less labor
energy and make it easier to operate. scissor jack is failed due to wear of teeth on both links at
lower end, Due to excessive use and high impact on screw starts getting wear and head of jack
starts bending due to the fatigue load acting continuously again & again over the head.
After reviewing all this work, we came to a compromise that there is a need to come up with a
new design which solves(bypasses) all these limitations. This project titled DESIGN AND
REALIZATION OF AN ELECTRIC CAR JACK FOR LIGHT VEHICLES It can be seen
from the examples above that some of these jacks are manually operated (they require
substantial human effort in order to function meaning the elderly and handicapped cannot use
them. Also, the fact that is manual implies it is time consuming, the designs either use gears, or
chain drive mechanisms meaning they are very costly to realize and require more maintenance
from time to time. Also, the system we are designing is an easy to use system for the
handicapped and the elderly.

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 CHAPTER THREE

MATERIALS AND METHODS

3.1 Materials
The materials involved in the realization of the hydraulic sheet metal shearing machine are listed
below:
Table 3.1. list of components and their various methods of production and availability
s/n Components Material made Method(s) of How the can be
of fabrication obtained
1 screw jack Steel Honing, Forging Obtained at
and casting, home country
Machining and
finishing,
assembly
2 DC wiper motor for Mild Steel Die-forging, heat Obtained at
vehicles treatment, home country
grinding
3 wire Cupper with Can be obtained
rubber coating at home country
4 switch Steel Obtained at
home country
5 Battery
6 Crocodile clips cupper
7 Base plate steel Obtained at
home country
8 Nuts Steel Machining, Obtained at
Casting, home country
threading
9 Bolts Steel Machining, Can be
Casting, manufactured
threading here

Methodology:
Methodology means a general guideline, steps, procedures that are followed during designing

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or solving of the problem.so this section of the report includes guideline system for solving the
problem which is stated in problem statement; with specific component such as phases, tasks,
methods, techniques and tool.
3.1 IDENTIFICATION OF THE NEED
First we have to identify the parameter that is needed or given in scissor jack design before we
start the design analysis. Such as
 The Weight of vehicle that the jack will lift
 Maximum height of jack that the jack could rise the vehicle
 Minimum height of jack
DESIGNING STEPS
Step 1: The first work on the design process is selection a proper material with suitable price and
best property should be chosen. We will select the materials based on the following criteria:
 Performance characteristics (such as mechanical properties): selecting the right material
with the right properties is needed.
 Processing (manufacturing) properties - simple way of producing is advantageous
step 2: Design and analysis of electric screw jack components
Step 3 cost analysis: - In this section we see the all cost the machine take to manufacture means
cost for labor, cost for each material, and cost of standard components of the electric scissor jack.

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Chapter four

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Chapte

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