GR0UP -10

PANKAJ KUMAR KUSHWAHAASHUTOSH TRIPATHI ASHUTOSH PANDEY BHUPENDRA YADAV

GUIDE. AST. PROF. SWATI SINGH

Study and Fabrication of

Forklift Truck Model

Project Title:

ABSTRACT• Material Handling is the movement, storage, control

and protection of materials and products. Material handling equipment are used to increase throughput, control costs and maximize productivity. Everything we use at some stage, has been stored and handled by materials handling equipment.

• A FORKLIFT TRUCK is a powered industrial truck used to lift and transport materials. It is an indispensable piece of equipment in manufacturing and warehousing operations. Lift trucks are available in many variations and load capacities. In a typical warehouse setting most forklifts have load capacities between one to five tons. Larger machines, up to 50 tons lift capacity are used for lifting heavier loads, including loaded shipping container.

INTRODUCTION• In general the forklift can be defined as a tool capable of lifting

hundreds of kilograms. A forklift is a vehicle similar to a small truck that has two metal forks on the front used to lift cargo. The forklift operator drives the forklift forward until the forks push under the cargo, and can then lift the cargo several feet in the air by operating the forks. The forks, also known as blades or tines, are usually made out of steel and can lift up to a few tons.

• Forklifts are either powered by gasoline, propane, or electricity. Electric forklifts relay on batteries to operate. Gasoline or propane forklifts are sometimes stronger or faster than electric forklifts, but they are more difficult to maintain and fuel can be costly. Electric forklifts are great for warehouse use because they do not give off noxious fumes like gas powered machines do.

• It is important for forklift operators to follow all safety precautions when using a forklift. Drivers should be careful, not to exceed the forklift's weight capacity. Well-maintained and safely operated forklifts make lifting and transporting cargo infinitely easier.

OBJECTIVES• To make forklift automatic

driven with the help of remote control.

• To improve load carrying capacity.

• To make material handling easy.

• Reduces fuel consumptions.

• To reduces accidental losses.

• To reduces the losses.

MECHANICAL STRUCTURE OF PROTOTYPEThe mechanical structure of this prototype module is constructed with square metal pipes, this structure looks like a rectangular box & the vertical moving mechanism that contains metal forks is assembled over the structure at front side. The entire vehicle is designed to drive through four wheels, & four motors are used to drive all the four wheels directly. Two left side motors of front and rear are connected parallel, similarly the other two motors used to drive right side front and rear wheels are also connected parallel. All these four motors are driven through a single ‘H’ bridge DC motor drive package. All the four wheels are directly coupled to the motor shafts independently.

All these four motors are driven through a single ‘H’ bridge DC motor drive package. All the four wheels are directly coupled to the motor shafts independently. The DC Motors are having reduction gear mechanism internally, there by speed is reduced and torque is increased. The reduction gear mechanism is Worm and Worm Wheel as shown in fig.

BLOCK DIAGRAM:

PROTOTYPE OF FORKLIFT TRUCK

Circuit board

Lift Gear

Fork

12V DC Battery

5V DC Motor

WheelReduce Gear Mechanism

COMPONENTS OF PROTOTYPE1. DC MOTOR:

Permanent magnet DC motor responds to both voltage and current. The steady state voltage across a motor determines the motor’s running speed, and the current through its armature windings determines the torque. Apply a voltage and the motor will start running in one direction; reverse the polarity and the direction will be reversed. If you apply a load to the motor shaft, it will draw more current, if the power supply does not able to provide enough current, the voltage will drop and the speed of the motor will be reduced.

2. TRANSMISSION SYSTEM:It is the measure of power or energy that is transferred from one point to another. In terms of the projects that are made in class, power transfer usually starts from the input and travels to the output. The input and output could be in the form of gears or gear trains.In this prototype, chain drive has been used.

CHAIN DRIVE SYSTEM:Chain drives, gear drives and belt drive systems are all effective power transmission choices. A system consisting of a chain and sprockets that is used to transmit motion is called a chain drive system.

Everyone has seen a bicycle or used one and noticed that it is driven by a large driver gear wheel with pedals attached. Smaller gears at the back are driven round, in turn driving round the back wheel. As the back wheel turns the bicycle moves forwards. Gears driven by chains are used in machinery, motorcycles and car engines and have many more applications.

This arrangement makes chain a strong and long lasting way of transmitting rotary motion from one gear wheel to another.

Bicycle Chain & Gear

Chain drive has one main advantage over a traditional gear train. Only two gear wheels and a chain are needed to transmit rotary motion over a distance. With a traditional gear train, many gears must be arranged meshing with each other in order to transmit motion.

WORKING PRINCIPLE

The principle is based on Law of Equilibrium of Levers i.e. the effort multiplied by its distance from the fulcrum equals the load multiplied by its distance from the fulcrum. It is also known as Principle of Counterbalance, like as in seesaw.

Centre of gravity : Centre of gravity of the truck is the point on an object at which all of the objects weight is concentrated. For symmetrical loads, the center of gravity is at the middle of the load.

DIFFERENT CENTRE OF GRAVITY:

The forklift and load must be considered a unit with a continually varying centre of gravity with every movement of the load. A forklift must never negotiate a turn at speed with a raised load, where centrifugal and gravitational forces may combine to cause a disastrous tip-over accident.A forklift truck’s ability to stay upright while it is in motion is its stability. It is the most important aspect to avoid accidents. The lateral stability of a truck changes depending on how high the load is lifted to. The rated lift capacity is reduced at increased lifting height.

And the Tilting Effect is shown in next slide.

.

Forklifts are rated for loads at a specified maximum weight and a specified forward centre of gravity. This information is located on a nameplate provided by the manufacturer, and loads must not exceed these specifications.

APPLICATIONS

• Loading & Unloading • Loading Dock

• Rack Storage • Truck Loading • Cargo loading at airports

• Block Stacking