INTERNSHIP REPORT / WCU 2022

WACHEMO UNIVERSITY

COLLAG OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINERING
FOUR MONTH ENTERNSHIP REPORT IN HOSSANA
POLYTECHNIC COLLAGE

NAME ID NO_
1. Shewalema Nibo………. 003844
2. Selamu Abriham ………. 004140
3. Admasu Demise ………. 0833/11
4. Behailu Tafese ….….…. 0854/11
5. Bereket Borsamo .……. 0824/11 Duration of internship, April to July
6. Teketel Hailu ……..…….. 004189 Date of submission, 09/03/15

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Declaration
We decelerate that the following report paper of the internship period is our original work and that all
sources of material used for this report have been duly acknowledged. All ideas that are mentioned on
the paper describe the real works that shown on the company. We also declare that this paper has not
been previously submitted in any means to any organization or person.

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Acknowledgement
First of all we would like to thank our Almighty GOD for his merciful and endless guidance throughout
our life and helping us to finish this internship successfully.
Secondly, we also indebted to express our heartfelt and deeper gratitude to our Advisors Mr. Bekele,
Mr. Mebratu, Mr.Semere, and Who advised & guided us, through following our daily progress, giving
fruitful comments, constructive corrections and very useful advice.
Next, we would like to give our best gratitude to Hossana polytechnic college for paving the way to our
job–training program by facilitating suitable working conditions and the workers of the college for
sharing useful skills, experiences and for their good interpersonal relationship.
The last but not the least, we would like to acknowledge Wachemo university, specifically Mechanical
Engineering Department, for giving this internship chance and for its provision of the necessary
funding that assisted us in successful completion of the internship program.

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Executive Summery
The internship activity starts at Hossana city with the hosting collage name is Hosaena polytechnic
collage (TEVT). It is located on North outskirt of the city around goburra sub city. This collage is one
of the biggest and the oldest collage having or including money department, machinery and automotive
dealer work shop in Ethiopia. Its future vision is to be the total solution provider to its customers in the
Construction, Automotive, GMF, Electricity and other scurvies. TEVT supplies its products to
agricultural, construction, transport and other sectors together with their workshop, field, training and
rental services indifferent ways. It has various governmental, non-governmental and private end users
and its overall organizational structure is suitable for executing respective tasks. We have spent our
internship period in Automotive technology workshop and field works in this section we have
performed according to its plan with regard to customer order. We have also taken reliable
measurements for respective challenges that are influence on us. We have benefited in improving
practical skill, theoretical knowledge, communication skills, team playing skills and leadership skills.
In addition to this the internship programs open an entrepreneur opportunity with good performances.
The collage has no Gear Box lifting machine also it has not any type of lifting machine to operate
engine overhauling. So this makes transmission maintenance difficult. it requires a lot of man power
for lifting the gear box. Hence, design of transmission gear box lifting machine and part of vehicle is
difficult and is carried out as a project. This project assures workers safety and saves waste of man
power. The design process is accomplished with the help of solid work software’s and it is presented
with various diagrams and graphs. The manufacturing cost is fair since it can be produced from
available and costly local steel products.

Key Word: automobile, Berthoud, design, device, gearbox,

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Contents
Declaration ................................................................................................................................................. I
Acknowledgement .................................................................................................................................... II
Executive Summery ................................................................................................................................ III
List of Figure ..........................................................................................................................................VII
CHAPTER ONE ....................................................................................................................................... 1
1.1 Introduction ......................................................................................................................................... 1
1.1 Background of the Institution.............................................................................................................. 1
1.2 History of the Institution ..................................................................................................................... 1
1.3 Hossana Polytechnic College’s Core Values ...................................................................................... 2
1.3.1 Vision ............................................................................................................................................... 2
1.3.2 Mission ............................................................................................................................................. 2
1.3.3 Values ............................................................................................................................................... 2
1.4 Main products and services ................................................................................................................. 3
1.4.1 Main products ................................................................................................................................... 3
1.4.2 Main services.................................................................................................................................... 5
1.5 Main customers or end users ............................................................................................................... 7
1.6 The overall organizational structure .................................................................................................... 8
1.7 Work flow ........................................................................................................................................... 9
CHAPEER TWO..................................................................................................................................... 10
2. OVERALL INTERNSHIP EXPERIENCE ........................................................................................ 10
2.1 How we got into the company........................................................................................................... 10
2.2 Section of company we have been working ...................................................................................... 10
2.3. Working Section Work Flow .......................................................................................................... 11
2.4 Work Tasks ....................................................................................................................................... 12
2.4.1 Valve Adjustment ........................................................................................................................... 13
2.5 Procedures we have been followed while performing tasks ............................................................. 14
Infrequent Use ......................................................................................................................................... 15

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2.6 Challenges We Have Been Faced ..................................................................................................... 16

2.7 Measurements We Have Been Taken to Overcome Challenges ....................................................... 16
CHAPTER THREE ................................................................................................................................. 17
3. BENEFITS OF THE INTERNSHIP ................................................................................................... 17
In terms of improving our practical, communication and leadership skill.............................................. 17
3.1 In Terms of Up Grading Our Theoretical Knowledge ...................................................................... 17
3.2 Interpersonal Communication Skill .................................................................................................. 18
3.3 In Terms of Improving Team Playing Skills ..................................................................................... 18
3.4. In Terms of improving leadership skills .......................................................................................... 18
3.5 Benefits we have gained in terms of understanding Work ethics ..................................................... 19
CHAPTER FOUR ................................................................................................................................... 20
4. DESGINE OF AUTOMOBILE GEARBOX HOLDING DEVICE ................................................... 20
4.1 Introduction ....................................................................................................................................... 20
4.2 Problem Statement ............................................................................................................................ 21
4.3 Objective of the project ..................................................................................................................... 21
4.3.1 General objectives .......................................................................................................................... 21
4.3.2 Specific objective ........................................................................................................................... 21
4.4. Scope of the project .......................................................................................................................... 22
4.5 Literature review ............................................................................................................................... 22
4.6 Methodology ..................................................................................................................................... 23
4.7 Design and analysis ........................................................................................................................... 23
4.7.1 Part of the Proposed Design ........................................................................................................... 23
4.7.2 Principles Operation of the Proposed Design ................................................................................ 24
4.7.3 Selection of Materials..................................................................................................................... 24
4.7.4 Design of main component ............................................................................................................ 25
4.7.5 Design of Gearbox Support Plate ................................................................................................... 26
4.7.6 Design of Power Screw .................................................................................................................. 28
4.7.7 Design of Link ................................................................................................................................ 31

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4.7.8 Design of nut .................................................................................................................................. 33

4.7.9 Design of pins................................................................................................................................. 34
4.7.10 cost analysis.................................................................................................................................. 34
4.7.11 Discussion of results..................................................................................................................... 35
CHAPTER FIVE ..................................................................................................................................... 36
5. Conclusion And Recommendation...................................................................................................... 36
5.1 Conclusion ......................................................................................................................................... 36
5.2 Recommendation ............................................................................................................................... 37
Reference ................................................................................................................................................. 38
APPENDECIES ...................................................................................................................................... 39
Appendices A: Part Drawing .......................................................................................................... 39
Appendices B: Assembly Drawing .................................................................................................. 43

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List of Figure
Figure 1 Block Machine ............................................................................................................................ 4
Figure 2 Brick Machine............................................................................................................................. 4
Figure 3 Tool room ................................................................................................................................... 6
Figure 4 production center shops .............................................................................................................. 6
Figure 5 sheet metal shop .......................................................................................................................... 7
Figure 6 the overall organizational structure............................................................................................. 8
Figure 7 Engine overhauling workshop .................................................................................................. 10
Figure 8 Engine room .............................................................................................................................. 11
Figure 9 Tasks performed in Engine room (Engine overhaul)................................................................ 13
Figure 10 Caliper gauge .......................................................................................................................... 13
Figure 11 Bench works ........................................................................................................................... 14
Figure 12 Brake pad life measuring instrument ...................................................................................... 15
Figure 13 Proposed Designs .................................................................................................................... 24
Figure 14 support plate with load distribution ........................................ Error! Bookmark not defined.
Figure 15 support plate ............................................................................................................................ 28
Figure 16 power screw ............................................................................................................................ 31
Figure 17 link .......................................................................................................................................... 33
Figure 18 pins ......................................................................................................................................... 34

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List of Tables
Table 1 material selection ....................................................................................................................... 25
Table 2 cost analysis ............................................................................................................................... 34

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CHAPTER ONE

1.1 Introduction

1.1 Background of the Institution

Hossana polytechnic College (HPTC) is currently one of governmental institution, which is under the
Federal Democratic Republic of Ethiopia Ministry of Education Technical Vocational Education and
Training (TVET). Originally HPTC is established for improve quality of Ethiopian manufacturing
sector by highly skilled manpower who will be engaged in innovative designing, problem solving
technologies and technology transfer, training center for industrial technology fields and studies. HPTC
is located in South Nation Nationality and People and Region (SNNPR), Hossana City and it is 230 km
away from the capital city of Addis Ababa. It trains students in twelve (12) main fields of study these
are; Manufacturing, Automotive technology, Electrical and Building Electric Installation, Electronics
and Industrial Machine Drives, Masonry, Sanitary, Surveying, Building Construction, Hotel and
Tourism, Textile and Garment, Information Communication Technology, Computer Science, Carpentry
and Furniture. From these our internship experience is under manufacturing department in production
center. There are five section of division in the Production center of manufacturing department, these
are; workshop section, machine shop section, welding section, sheet metal section, and metal forming
section. Gives job opportunities for the outstanding trainees on that campus.

1.2 History of the Institution

The current Hossana Poly technic collage was established in 1990 under the name Hossana technical
and vacational training center and the number of departments was only 6. t was given a year’s training
at that time there were 14 employees including teachers and currently there are 26A level ,147B level
and 39C level in total 212 trainers. In 1994 according to the national technical and vocational education
and training strategy, it has been providing training for one to three years depending on the nature of
the field of study. since 1998, it has been known as Hossana technical and vocational educational and
training collage, and since Feb 2003 EC, it has been named Hossana poly technic collage and has been
providing training with competence, quality and efficiency. This year, the collage has opened more
than 20 professional fields with teachers and administrative staff who have graduated from higher
education’s institutions and have received and trained more than 5996 trainers in regular and evening

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programs. Hossana poly technic college one of the oldest technical and vocational education and
training collages in our region and is the only college in the region that is a leader in the field of
constriction training. therefore, the trainers who graduate from the collage are playing a leading role in
constriction in our region and nationally, and the collage is currently providing complete training in the
fields of training listed below.

 Construction Technology Sector

 Industrial Technology Sector
 ICT Sector
 Hotel and Tourism Sector
 Culture and Social Service Sector
 Municipality Service Sector

1.3 Hossana Polytechnic College’s Core Values

It minimize poverty from country and contribute to social and economic development by creating
competent, motivated and creative work force in the country. This is implemented by facilitating high
quality technical and vocational education and training based on the needs of all economic sectors for
all people who want to develop their knowledge and skills at levels.

1.3.1 Vision
The core vision of HPTC’S is contributing competent, qualified professionals and self-confident in
their profession in regional and national economic, social activities in order to promote radical change
in poverty reduction by building sustainable development of the nation.

1.3.2 Mission
Based on tangible and result oriented training system giving practically supported training in modern
way for highly skilled trainees and building their entrepreneurship performance and outsource
internationally competitive, creative and professional trainees.

1.3.3 Values
The core values of HPTC are as follows:

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 Continuous professional advance

 Self-confidence
 Being respectful for values of ethics
 Entrepreneurship
 Top respectful personality and be exam plenary
 Developing culture of working together
 Inspiring and appreciating innovations and creativity
 Promoting Transparency and accountability
 Tolerance of diversity in Ethnicity, political views and religious status.

1.4 Main products and services

1.4.1 Main products

Hossana Polytechnic College production center mainly produce (manufacture) the following products
in according to a customer order.

 office tables and chairs

 Shaft
 class room chair
 Pulley
 L-T-Z metals for construction
 Gear, usually spur gear
 bread baking rectangular dishes
 Block machine
 metal electric poles(bawuza) Hose adapter
 Brick machine
 Master pin
 Different types of screw thread
 Keys
 House windows and doors
 Roller

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Figure 1 Block Machine

Figure 2 Brick Machine

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1.4.2 Main services

Hossana Polytechnic College offers the following services for its customers. Some of them are:

 Gives professional support and consulting service for small to medium work enterprises.
 Transferring of technology
 Produce innovative and problems solving products for the community
 Consulting different enterprises for wachemo university and other governmental and non-governmental
organization

Production Center Departments

Under the manufacturing department, the production center department is organized in to five (5)
divisions, it includes:

 Workshop
 Machine shop
 Welding shop
 Sheet metal shop
 Metal forming shop

For all of the divisions in the production center department there is a tool room. This tool room is a hub
for all kind of tools which is found on the production center, and this room applies the Kaizen
philosophy ‘5S’ (sort, stabilize, shine, standardize, sustain) and its advantages in workshop
management as shown below:

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Figure 3 Tool room

 Some of the production center sub-departments are:

a. machine shop b. welding shop

c. work shop d. metal forming shop

Figure 4 production center shops

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Figure 5 sheet metal shop

Main production process

The main production process of the college is start by producing quality students with knowledge and
skill in enterprises level for the help of the community

The college produces productive students by different level of studies. Such as, theoretical studies and
practical project training for solving Community based problems.

There are different projects and machine parts in a machine shop and other sections of the department.
Its main purpose is technology transferring and crating job opportunity for the community and small to
medium work enterprises.

1.5 Main customers or end users

The main customers or end users of the collage are described as follows:
 Society
 Students
 Enterprise
 Workers in the collage and etc…

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1.6 The overall organizational structure

Figure 6 the overall organizational structure

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1.7 Work flow

Problems from customers or from the sections in the company is brought to this section and, the
workers in the section will discuss over the problem and on the task every worker will participate
according to fields of study and one person will take the responsibility. Then term by term presentation
within the given time they discuss with the workers and the customers with the cost of manufacturing.

Then with proper manufacturing drawing and technological procedures it is distributed to factory
manager, operation PPC, marketing, finance and property administration, and to machinists. Then
feedback is taken and delivered to the customer.

Customer Product process Manufacturing Delivery

needs(Requirements) design design process and
procedures procedures control process

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CHAPEER TWO

2. OVERALL INTERNSHIP EXPERIENCE

2.1 How we got into the company

After we got the letter requesting for internship place from the department, our friends assigned one of
their friends to take the papers to the collage to request for permission and took the papers to the
college automotive department and told them that their request was confirmed. At the brake time we
met Mr.Dilebo mechanical engineering department industrial linkage, and he made contact with the
college.
The first day we got into the college we joined the college’s human resource department. Then we were sent
to the automotive department. Then we meet Mr. Sultan and Mrs. Yohanis showed us all blocks or factories
where we were going to work. Then they introduced us with the workers of shops. And within few days we
became familiar with the environment and gained a general overview.

2.2 Section of company we have been working

During our internship time we have been working under technique department in overhaul maintenance
case team and we spend our time in Hossana polytechnic collage. In this case team there are different
departments it will concern different duties;
Engine overhauling service department,
These departments cover maintenance of engine, flywheel, gear box and differentials.

Figure 7 Engine overhauling workshop

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Figure 8 Engine room

Electric overhauling department,
This department covers maintenance of electrical circuit and electrical components
Accessory overhauling department,
This department covers accessory maintenance of the buss like turbo charger, door cylinder and valve
etc.
Fuel system overhauling department
This department covers maintenance of fuel system from starting from the tank to injector nozzle.
Radiator system overhauling department
This department covers maintenance of radiator system like house, thermostat and radiator etc. Most of
our time during the internship is spend on engine overhauling department and side to side we work
almost in all departments Work flow of the overhaul maintenance case team; Depending on the type of
damage the car is send to appropriate department and the chief mechanic will distribute the work to the
fellow worker.

2.3. Working Section Work Flow

When customer come to company the reception takes information of the car on the work order. If the
car needs Service we have to know how many kilo meters it travels and in what type of area it is
driven. Sometimes based on the areas, where car works, condition parts can be changed even before it
reaches its service limit. Based on the information on the work order the technician sees the car and list
the parts required to be changed and give to the ware house coordinator. The ware house coordinator
cheeks the parts on-line and prints the work order, which has the list of parts and its price, for the part
speaker and customer. Then, the part speaker collects and brings the parts for the technician. As the

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ordered parts gets ready the technician starts his job. But if the customer only wants to buy, then he/she
go to the seal counter. The seals counter sends the list to the ware house coordinator.

2.4 Work Tasks

 By the time we spent in company we mainly worked on giving;
 Regular service to cars

 Engine overhaul service

 Valve adjustment

 Electrical machine maintenance (stator, alternator, AC generator) and ignition key, switch, tape and
cable replacement.

 Maintenance of clutch and brake systems (both internal expanded and external expanded disk brakes)

 Car services (fuel filter and oil change after usage)

 Maintenance of fuel injections

 Transmission maintenance (differentials, both automatic and manual gear boxes) Adjustable and

portable engine test stand design for all ford vehicle engines.

(a) cylinder block (b) cylinder head

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(c) Connecting piston and connecting rod with piston pin (d) piston rings compressor

Figure 9 Tasks performed in Engine room (Engine overhaul)

2.4.1 Valve Adjustment

We need to check and adjust valve clearance because too much clearance which make the engine noisy
and also will lost its performance. If the clearance is too tight, damage on engines may occur. So, we
have to inspect and adjust the valve clearance. Troubleshooting: car highly release black smoke
Equipment: caliper gauge

Figure 10 Caliper gauge

Cylinder which is free (i.e valve knob turns up ward and it is not pushing rocker arm) and its nut not
moving is the one with problem. Make valve arrangement by tightening and loosening the nuts by
checking the valves clearance by using caliper gauge. 0.15mm must pass through inlet valve clearance;
0.25mm must pass through exhaust valve. Exhaust valve clearance is greater because each cylinder has
two inlet and one exhaust valves so it has to be wider to remove the end product.

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2.5 Procedures we have been followed while performing tasks

General the following method and procedures have been followed while performing tasks.

• First, before getting in to work wear safety clothes and shoe. The rule SAFTY FIRST is really
applicable here.

• We request work order from the customer. Based on the information on the work order the technician
sees the car.

• If it was simple task such as regular service we had done by ourselves rather we have asked help from
others. That is

• First, we drain out the engine oil to replace with the new one, due to high heat generated by the engine
and for different reasons Engine oil gradually lose its property (viscosity) so it must be changed every
5000 km.

Figure 11 Bench works

• If the car is diesel engine we have to flush the engine first to clean. By inserting the flush oil and start
the motor about 20- 30 min. During flushing takes place we inspect brake pads and disc.

• Due to rubbing friction between brake disc and pad, in braking system, the pad may need inspection
and replacement. Disc pad has its own instrument to measure its life time so we inspect using it. if the
depth in the pad fits with the greens height then its good, if it reaches yellow one its warning and by the
time it reaches the red pad needs to be replaced no longer it gives proper service.

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Figure 12 Brake pad life measuring instrument

• We also inspect and clean back wheels brake drums with sand paper and wash the brake shoes. After
20 -30 min we drain out the flush oil and replace the new engine oil and replace oil filter and fuel
element, inspect air cleaner, battery, steering wheel linkage and steering gear box oil, tightening of
propeller shaft bolts and nuts, front and rear suspension and external leakage if any.

• Lubricating steering system like steering knuckle, drag link, king pin, center arm and alsopropeller
shaft with grease and finally we inspect or check if any problem in lighting system, horn, wiper and
washer system.

Infrequent Use
If your vehicle normally travels less than 5000 km in three months, we recommend that your vehicle is
serviced at least once every three months Since gear and differential oil and brake pedal renewed at
longer kilo meter most of the time we are familiar with changing engine oil, fuel, air and Ac filters. To
change engine oil first remove the guard underneath oil sump. By preparing oil dish uptight the nut by
choosing socket, which fits with the nut, by using ratchet. Also remove oil filter. Wait till the oil fully
discharged from the sump. Tight back the sump nut while put back the new oil filter back. Based on the
cars refill capacity refill the engine oil 8lit or 6.7lit (cheek by deep stick whether it’s full or not). I.e. for
safety during gear box and differential oil discharge always open first pouring hole, since its serviced

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after long period of time it may be comes difficult to open pouring hole after discharging the oil, but its
better with unchanged oil than empty box.

2.6 Challenges We Have Been Faced

 By the time we spent in the company we had faced challenges, among this;

 As we begun to work shop there were many students but only one technician so there was crowdedness
to clearly see and practice what he was doing.

 Safety guards (safety shoes and glove) were not fully provided during work.

 Offices were not available to accomplish our paper.

 Materials which used for manufacture our design project didn’t purchase. As a result the project
prototype was not produced.

 Some tasks were requiring higher labor forces.

2.7 Measurements We Have Been Taken to Overcome Challenges

There were challenges during our work. In order to overcome these challenges and achieve our goal it
was critical to take the right measurements as the challenges were happen. Among those some of them
are listed below. Such as:

• To avoid the crowdedness we had been grouped in to two group and starts to work in shift.

• We individually collected useful automotive manuals (in soft and hard copies) from the technicians.

• When there were no work, Since the workers are friendly we asked them to share us their knowledge in
their free time so they told and show us what we have to know.

• To solve the problem related to the time wasted by waiting the component sent to machine shop we
decided to design some machines to do the task there.

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CHAPTER THREE

3. BENEFITS OF THE INTERNSHIP

In terms of improving our practical, communication and leadership skill

This internship program enables the students to relate theoretical knowledge they gained in the school
with real world practice. The students will also develop skills in safety practices, work ethics,
communication and management; this program will also enable students to have a closer relationship
with the host companies. Generally, the objectives of this training program are:

 To integrate theory with practice: students must be proficient in applying the official and technical
knowledge in to real working environment

 To allow the students adapt with real working environment. Also for taking preparation before making
choices in the careers. After completing our studies.

 To give opportunity for students to work with experienced company technicians.

Enhances skills in technical report writing and communication.

3.1 In Terms of Up Grading Our Theoretical Knowledge

By the time we spent in the company we had seen practical knowledges on different parts of vehicles
(automobiles), which mainly concerned on our internal combustion engine and especially motor
vehicle course we had taken in the school. such as working principle of;

• Four-wheel and two-wheel drive vehicles.

• Transmissions (automatic and manual transmission and differential gearbox).
• Car battery, alternator and starter motors.
• Radiators for engine cooling system.
• Clutch and braking systems.
• Turbo chargers and inter coolers. And,
• Properties of various oils, gasoline and diesel.
i.e. suspension system, braking system, power train, engine and etc.

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3.2 Interpersonal Communication Skill

During the internship program we were trying to develop our interpersonal communication skill with
the process by which we exchange information feelings and face-to-face communication. We had
improved our communication skills in a good manner which we could talk to any person at the site
with confidence and easily as possible in our experience. We had observed that communication
between different sections of the project is vital to attain high efficient on work.

3.3 In Terms of Improving Team Playing Skills

Team playing skills means the activity of working well together as team to solve or shear the ideas and
challenges. When we stay in HPTC, we have learned that it is difficult to go ahead with the automotive
industry without having a strong team. Teamwork is important because, it can speed up process and
make things run more efficiently and allows goals to be reacted in an efficient and timely method. A
good team will generate and further bond of trust and confidence both in themselves and one another.
This was positively affecting our self-steam, self-confidence in our life, and possibly our loyalty to the
company increasing productivity and ultimately, company profit. We have developed the following
values after improving team playing skills when we stay in HPTC.

• Commitment
• Communication
• Decision making
• Tolerance of diversity and,
• Respecting others

3.4. In Terms of improving leadership skills

Achieving leadership skills require a high level of commitment to learn from each experience. We have
observed that a good leader is individual who is focus on one common goal developing the collage by
making the working air suitable and work with his employers peacefully. One should have great skills
to be a leader ship, these are:

• Great listener
• Take ownership and responsibility

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• Communicate effectively
• Commitment, integrity and passionate
• Good management skill
• Encourage others through positively
This we have maintained the following values after improving leadership skills.

• Taking responsibility
We have taken any responsibilities which are essential to our work. Hence leadership requires taking a
responsibility of tasks, agreements and protocols.

• Loyalty
We are being loyal to serve our customers, servants, companies and country since we will employ
through those elements.

• Self-confidence
Good leadership by itself requires very confidence educated person. This we have good self-confidence
to achieve our goal and manage others.

• Confidential/keeping secret/
We have kept companies secret when we will employed.

• Unbiased decision maker

3.5 Benefits we have gained in terms of understanding Work ethics

Work ethics are standards, principles or values that are generally based on conscientious. Mostly work
ethics are thought to a benefit of a person morally, thereby improving their character. Work ethics is
the core idea when you are in some staff, sounder standing of work ethics is crucial, the internship
program helps us:

 To respect the entrance and working time in HPTC/TEVT being punctuality.

 To respect others in the work place.

 To prevent any kind of corruptions.

 To respect any kinds of job.

 To prevent me from addicted drugs in the workplace.

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Additionally, we have gained a good work ethics, such as:

• Reliability
• Dedication
• Productivity
• Cooperation

CHAPTER FOUR

4. DESGINE OF AUTOMOBILE GEARBOX HOLDING DEVICE

4.1 Introduction
One of the greatest inventions of engineering, automobile has all the time undergone servicing and
maintenance. It is useful and does a lot of work. However, sometimes, because of the improper way it
is handled, and also, due to accidents, it develops faults and this results to its breakdown. Most
automobile breakdowns are caused mainly by problems with the engine, gearbox or suspension. The
application of stress to any material will lead to the production of elastic and/or plastic strain and if the
stress is increased progressively, fracture will ultimately occur. The safe operation of a vehicle support
is dependent on its condition in use, and deterioration would lead to a significant risk to the operator.

Hossana polytechinic share company is a dealer of ford, Massey Ferguson and caterpillar’s products.
Those all companies machinery is run with various sized engine. The maintenance vehicle gear box is
held in the workshops of this company. Maintenance of gear box requires more time, skilled man
power and portable equipment to assure safety of the machinery. So, reliable gear box holding/lifting
machine is very essential equipment to perform this action. Uncrowded space and good equipment are
needed to achieve maintenance quality. Portable gearbox lifter is designed to address maintenance
quality and clients want. It is used for lifting gear box at the required places.

In order to avoid breakdown, vehicles must be serviced and maintained at regular intervals and, in the
event of a breakdown, action must be taken to clear the road and repair the vehicle so as to restore it to
good working condition, as quickly as possible. In most countries it is the motor vehicle repair and
maintenance industry that performs the bulk of vehicle maintenance and repair work. Many parts

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producing and mechanical devices manufacturing companies as well as individual engineers have tried
many useful attempts to solve this gearbox removing problems. Sometimes the automobile or vehicle is
lifted a little high above ground level with different types of lifting devices in order to perform
maintenance work on components beneath the body of the car but when the gearbox has to be replaced
or removed from its position a special device will be required to perform such a function. Some of
these attempts have resulted in the invention of special devices such as the jib and the hydraulic
transmission jack. Some designs of the transmission jack are operated by foot and others with the hand.
Most of these jacks are bulky, very expensive and too high to be used under vehicles that are not jacked
up too much. The objective of this work is to design a device that is reliable ergonomic efficient cost
effective and safe in order to minimize and eliminate the risks involved during gear box maintenance.

4.2 Problem Statement

The gearbox is too heavy to hold/lift. It gets repaired when automobile stops working as a result of
transmission failure. In the collage technician’s use dangerous lifting way to remove and replace
gearboxes. Six men are involved during the process of removal/replacement of the gearbox from the
flywheel and the clutch. About four of these men support the gear box beneath the automobile While
the other two in the cab hold ropes wrapped round the gearbox to lighten the load of the gearbox for the
other. This results in waste of time and man power and may also cause dangerous on the tool. It’s risky
for peoples’ life. So, the objective of this work is to design a device that is reliable ergonomic efficient
cost effective and safe in order to minimize and eliminate the risks involved during gear box
maintenance.

4.3 Objective of the project

4.3.1 General objectives

The main objective of this project is to design a simple automotive gearbox holding device/machine for
the company.

4.3.2 Specific objective

• To solve the problem of the company related to gearbox holding device
• To reduce danger on the safety of mechanics

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• To save working time

• To reduce cost

4.4. Scope of the project

The scope of these project is to design gearbox holding\lifting device which is made up of several
separate components put together to form a linked mechanism. It has a support plate on which the
gearbox will rest. There are also the links, joined together by pins to the brackets and the joints as
shown in figure 4.1. This mechanism makes the up and down movement of the support plate possible
when the power screw connecting the two brackets is turned either clockwise or counterclockwise. The
device also has a base in the form of a board with wheels to make easy the drawing and pushing of the
device with the gearbox on it.

4.5 Literature review

The formation of any business begins with someone producing the initial idea for the project. The
continued success of an established business depends upon the number and quality of the ideas fed into
it. Without a continual row of new ideas, a business cannot function profitably or expand successfully
and must, therefore eventually fade into total obscurity Ideas for a new business project, a new product,
a means of reducing manufacturing costs, or for solving industrial labor problems, begin in the human
mind. Most people conceive their ideas unconsciously, and because they are unaware of the mental
mechanics that caused the ’idea’ to be produced they cannot repeat the ideation process to produce
further profitable ideas at will. Fortunately, there are available established creative techniques which,
when used correctly, do enable a person to produce a large number of first-class ideas at will. Here, we
have tried our best to combine all the necessary data for the design of this machine. This we presented
the data about general design and some note on components of the machine. [6]

There are many industries in which use many material lifting devices for proper material handling and
safety purpose like manual material handling, power operated material handling. Production on a tall
machine it difficult to carry material on machine, holding job on machine is difficult. For those
purposes we make a suitable handling device name is "automobile gear box holding device". In this
device we use a power screw mechanism and trolley mechanism combine for a lifting of a heavy gear
box. Power screw are used to convert rotary motion into translator motion, for example in case of lead

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screw of a lathe machine, rotary motion available but tool has to be advanced distance in direction of
cut against the cutting resistance of a material. In case of screw small force applied in horizontal plane
is used to raise or lower the large load. Power also used in toggle jack, screw jack, vice, material testing
machine etc. [2]

4.6 Methodology
To develop our title, we are interview mechanics who are working in HPTC and looking the problems
they faced when thesy work in a garage and different workshops. We also directed and inspired by our
director in HPTC to solve different problems of the industry like this by:

Assessing problem in the shop

Asking the worker in the shop
Discussing within our team member
• Mathematical Analysis using the collected information.
• Design analysis by analyzing
- The force acting each part
- The stress induced by force acting in each part

4.7 Design and analysis

4.7.1 Part of the Proposed Design

 Support plate
 Link

 Screw

 Hand bar

 Frame

 Pin

 base

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Figure 13 Proposed Designs

4.7.2 Principles Operation of the Proposed Design

This design operates on the same principle on which a bolt and a nut operates in that when a bolt
rotates in a nut, it changes rotational angular motion to linear motion to transmit power or to develop
large forces. In this design, only one of the two brackets has its hole threaded. The other one has a
smoothed hole. The portion of the power screw that is through this hole is also smoothened to facilitate
its rotational movement in the hole.

 The operator/mechanic turns the bar with his hands in a clockwise direction for makes it go up.

 When the screw lifts the load on the platform which placed above will also be raised.
 The bar is turned until the jack is raised to the level needed.
 To lower the jack the bar is turned in the opposite direction.

4.7.3 Selection of Materials

The selection of a proper material, for engineering purposes, is one of the most difficult problems for
the designer. The best material is one which serves the desired objective at the minimum cost. The
following factors should be considered while selecting the material:

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1. Availability of the materials,

2. Suitability of the materials for the working conditions in service, and
3. The cost of the materials.
The important properties, which determine the utility of the material, are physical, chemical and
mechanical properties. The mechanical properties of the metals are those which are associated with the
ability of the material to resist mechanical forces and load. These mechanical properties of the metal
include strength, stiffness, elasticity, plasticity, ductility, brittleness, malleability, toughness, resilience,
creep and hardness.

AISI 1025 steel with density 7.858 g/cm3, modulus of elasticity E 207 GPa, Poisson’s ratio 0.30, yield
strength 370 MPa and a tensile strength of 440 MPa is selected for all the components,

Table 1 material selection

Mechanical property AISI 1025 steel

yield strength 370 MPa

tensile strength 440 MPa

Density 7.858 g/cm3

modulus of elasticity 207 GPa

Poisson’s ratio 0.30

4.7.4 Design of main component

In order to reduce material cost and component over design, a factor of safety 3 would be used for the
proposed design. (n=3).

The device is designed to support a maximum weight of 2000N. When the jack is in the top position
the distance between the center lines of nuts is 400 mm and in the bottom this distance is 1000 mm.
The eight links of the device are symmetrical and 350 mm long each. The link pins in the base are set
400 mm apart.

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4.7.5 Design of Gearbox Support Plate

The support plate with the load distribution is shown in figure 4.2

Figure 14 support plate with load distribution

Weight of gearbox, W = 2000 N

Reactions at the supports, R

ƩR = 4 R =2000

R = 2000/4 = 500 N

Assuming the Gearbox Support Plate to be a beam subjected to bending and shear stress, then applying
the maximum shear stress theory;

= = [ ............................(1)

= yield strength of material

Also, maximum bending momentum of, = …………………. (2)

Maximum shear stress, = …………………………………………… (3)

W = 2000 N

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RA 500mm RB

Take section xx from (0 0.25)

Wx +M

RA

X -V

Ʃ Fy = 0 ƩMsec = 0

-V W =0 M ( RA =0

-V 2000X 500 = 0 M ) – 500x = 0

V =-2000X M = -1000x²

Substitute the value of x, (x = 0, 0.25, 0.5)

Mmax = 62.5 N/m and V = 500 N

Substituting these values into equations 2 and 3

= =

Cross-sectional area A= bh =0.5h and c = h/2

I=

= =

h = 8.98 mm say 10 mm

h =10 mm

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Figure 15 support plate

4.7.6 Design of Power Screw

The Power Screw is shown in figure. A little consideration shows that the maximum load on the square
threaded screw occurs when the jack is in the bottom position. The position of the link CD in the
bottom position is shown in Fig

300mm
Let θ be the angle of inclination of the link CD with the horizontal

From the geometry of figure, we find that

= = 31

Each joint carries half the total load on the jack and due to this, the CD link is subjected to tension
while the square threaded screw is under pull. The magnitude of the pull on the square threaded screw
becomes;

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F= ……………………………………………… (4)

F=

F =1664.3N

Since a similar pull act on the other joint, therefore total tensile pull on the square threaded rod,

W1 = 2F = 2

W1 = 3228.55 N

Let dc = core diameter of the screw,

We know that load on the screw, (W1)

W1 =

3328.56 =

dc = 3.07mm say 4mm

Since the screw is also subjected to torsional shear stress, therefore to account for this, let us adopt

dc = 40 mm

Using a pitch of 6 mm, normal or outer diameter of the screw,

do = dc 40mm 6mm = 46mm

And mean diameter of the screw,

d = do = 46mm

d = 43mm

Let us now check for principal stresses. We knew that

tan = = 0.444……………. (

And the effort required to rotate the screw,

P = W1 ( ) = W1 ( )……………………………………… (5). Khurmi and Gupta, (2005)

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Using a coefficient of friction, = 0.2

P = 3328.55 ( = 819.37 N

Therefore, Torque required to rotating the screw,

T=P = 819.37 = 17.61 Nm, or 17610 N-mm

and shear stress in the screw due to torque, = ……………………… (6)

= = 1.402Mpa

Also, direct tensile stress in the screw.

= ………………………………………………………………… (7)

= = 2.6501Mpa

Maximum principal (tensile) stress,

…………………………………….. (8) Khurmi, (2005).

t (max)= = 3.2570Mpa

And maximum shear stress,

max= =1.9315 Mpa

Since the maximum stresses are within safe limits, therefore the design of the square threaded screw is
satisfactory.

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Figure 16 power screw

4.7.7 Design of Link

Due to the load, the links may buckle in two planes at right angles to each other. For buckling in the
vertical plane (i.e. in the plane of the links), the links are considered as hinged at both ends and for
buckling in a plane perpendicular to the vertical plane, it is considered as fixed at both
ends……………………………………………………………… Khurmi and Gupta, (2005).

The maximum Load on link=F/2= 1664.3/2 = 832.25 N

The links must be designed for a buckling load,

Wcr = ………………………………………………………………………….………..(7)

Assuming factor of safety is 3,

Buckling load on the link, Wcr = 832.25 = 2494.45 N

Let t1 = thickness of the link, and

b1 = Width of the link

Assuming the width of the link is two times the thickness of the link, i.e. b1 = 2t1,

Then the cross -sectional area of the link, A = t1 2 t1 = 2(t1)²

And moment of inertia of the cross-section of the link,

I= (b1)³ = (2t1)³ = 0.67(t)ˆ4

Radius of gyration,

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K= = = 0.578t1…………………………………………………………….(8)

For buckling of the link in the vertical plane, the ends are considered as hinged Khurmi, (2005),

Therefore equivalent length of the link, L= l (length of link) = 0.35m

And Rankine’s constant,

a= = = 0.0001811

According to Rankine’s formula, buckling load ( Wcr ),

2494.5 = = ► =

3.37 =0

= = 5.249 say 8mm …(take sign )

t1 = 8mm

and b1 = 2 16mm

Now considering the buckling of the link in a plane perpendicular to the vertical plane moment of
inertia of the cross-section of the link,

I= (t1)³ = (t1)³ = 0.167(t)ˆ4

Radius of gyration,

K= = = 0.288t1

For buckling of the link in a plane perpendicular to the vertical plane, the ends are considered as fixed,
therefore Equivalent length of the link,

L= = = 175 mm

Again according to Rankine's formula, buckling load,

Wcr = = =

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Substituting the value of t1 = 8mm, gives

Wcr = = 23160.67N

Since this buckling load is more than the calculated value (i.e. 2494.5 N), therefore the link is safe for
buckling in a plane perpendicular to the vertical plane.

Therefore We may take t1 = 8 mm and b1 = 16 mm

Figure 17 link

4.7.8 Design of nut

Let n= number of threads on nut.

Designing the nut in bearing of threads,

For the nut to be safe in tension, n = 4

dc =40 mm Here, pitch, p=6,

The thickness of the nut,

t=n =4

Thickness of threads, t = p/2=3

The width of the nut (b) is taken as 1.5 do

b = 1.5 (46 mm) = 69mm

To control the movement of the nuts beyond 1000mm (the maximum distance between the
centre lines of nuts), rings of 8 mm thickness are fitted on the screw with the help of set screws.

Length of screwed portion of the screw,

=1000 Thickness of rings

=1000 8 =1040mm

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4.7.9 Design of pins

The pins are in double shear. If dp is the diameter of pins then

dp = = = 4.6mm say 8mm

Diameter of pin head=1.5 dp = 1.5×10=15 mm

Thickness of pin head be taken as 5 mm.

Split pins are used to keep the pins in position.

Figure 18 pins

4.7.10 cost analysis

The analysis of cost is made for all components based on cost of raw material.
Table 2 cost analysis

Item No Description Material Quantity Cost Total cost in

ETB

1 Support plate AISI 1025 1 1200 1200

steel

2 Link AISE 1025 8 100 100.1

steel

3 Screw AISI 1025 1 500 500.2

steel

4 Hand bar AISI 1025 1 150 150.3

steel

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5 Frame AISI 1025 2 350 700.3

steel

6 Pin AISI 1025 steel 8 40 320.20

7 Base AISI 1025 1 1200 1200.5

steel

Total 4170.34

This design takes total amount of 4170.34 birr, but the machine takes a lot of money in the market. So
it’s cost effective and can be purchased easily if its supplied to the market.

4.7.11 Discussion of results

A device which is efficient, reliable, ergonomic, safe and cost-effective device to hold
the automobile gearbox in position during its maintenance has been designed. Figure 13 shows the
proposed design. The Principle of operation of the design is easy and user friendly. The rotation of the
power screw causes the bracket with the hole threaded to move axially back and forth on the screw
enabling the links to oscillate and move the support plate up or down depending on the direction of
rotation of the screw. The major components of the design (Gearbox support plate, power screw, link,
base, hand bar, pins and frame) are easy to fabricate and install.

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CHAPTER FIVE

5. Conclusion And Recommendation

5.1 Conclusion

In the company Ford service workshops has no gear box transmission lifting machine. Thus by means
of theoretical calculation effective and portable gear box lifting machine is designed in this paper. By
this design Workers safety is assured and service and supply time for the customers reduced.
Adjustable and portable gear box lifter is important to hold and lift during service. Keeping all
accessories on the lifter, assures maintenance quality. Manpower required to lift the gear box is
minimized with the help of this lifter. Since it uses available and costly materials it creates substantia
economic benefits to the producing enterprise. At the end of this project we are very glad to present it
and are totally satisfied about it.

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5.2 Recommendation
The company should give more opportunity for students to engage in this interesting company since
there is various practical activities initiate the students to create new inventions. Internship student
should be count as one worker during any task. Facilities should be full filed to implement students’
project to practical activities. Working environment should be clean and fresh which maintain workers
safety and production quality.

Future Scope

The hand lever will modify by using a gear drive it helps to minimize the effort, it can be use in more
efficient way. It reduces fatigue to the operator. The sizes of links and dia. of the screw can be increase;
it increases the load carrying capacity and handles maximum heavy loads. The device can be drive by
using electrical motor drive the automation can be done. It can be improve the efficiency of the whole
device.

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Reference
[1] International Journal Of Engineering And Science Vol.2, Issue 9 (April 2013), Pp 10-1,

[2] International Journal of Science, Technology & Management Volume No.04, Issue No. 01, January
2015

[3] R. S. Khurmi and J. K. Gupta a textbook of machine design 2005 Eurasia publishing house (pvt.)Ltd.

[4] R. S. Khurmi and J. K. Gupta theory of machines .

[5] Rise engineering shear company documentations.

[6] V. B. Bhandari design of machine elements (Tata McGraw-Hill Education 2010).

[7] www.machinedesign.com.

[8] www.ctr.design.co.uk
[9] Jonson, J. (2021, 1 13). www.gearmotions.com.

[10] Kannaiah, D. (2006). Machine drawing. New Delhi: New age international (P) limited.

[11] Kramer. (2021, February 2). www.wonststor.com.

[12] Khurmi, R. (2005). A text book of machine design. Ram Nagar, New Delhi 110 055:1 Eurasia
publishing house(PVT) LTD.

[13] MTN, M. (June 2011). Design, construction and performance analysis of an engine stand for light
vehicle. International Journal Of Engineering and Technology (IRJET), 3-5.

[14] Rolls-Royee. (July 2014). Design consideration of engine stand. Intrnational Journal For Innovative,
450-456.

[15] Shigly. (2001). Mechanical enginering design. New Delhi: McGraw-Hill.

[16] Torin. (2018). Design and fabrication of engine stand. Reserch Gate, 40-42.

[17] Wiliam. (2021, 1 13). www.eastwood.com.

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APPENDECIES
Appendices A: Part Drawing

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4 3 2 1

F F

E E

D D

C C

B UNLESS OTHERWISE SPECIFIED: FINISH:

DIMENSIONS ARE IN MILLIMETERS
DEBURR AND
BREAK SHARP DO NOT SCALE DRAWI
NG REVISION
B
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:
NAME SIGNATURE DATE TITLE:
DRAWN
CHK'D
APPV'D
MFG
Q.A MATERIAL: DWG NO.
A4
A WEIGHT: SCALE:1:5
shewa link 2 SHEET 1 OF 1
A
4 3 2 1
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Appendices B: Assembly Drawing

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