This design details the hydraulic floor jack's construction.

1. ARBA MINCH UNIVERSTY
ARBA MINCH UNIVERSITY INSTITUTE OF
TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
MACHINE DESIGN PROJECT - 1 HYDROLIC FLOOR JACK:
BY:
NAME: ID NO
1. MIKIAS TEWACHEW……………………NSR /1701/12
2. LEUL ALEMU……………………………..NSR/ 1488 /12
3. HIMANOT MATEBE…………………….NSR/1283

2. CHAPTER ONE
INTRODUCTION
 Jack’s can be usually classified based on the type of
force they employ: mechanical or hydraulic. Mechanical
Jack’ lift heavy, light vehicles and are rated based on
lifting capacity (for example, the number of tons it can
lift). Hydraulic Jacks are stronger than mechanical
Jack’s and can lift heavier loads with applying small
efforts, its classified as bottle Jacks and floor Jacks.
Hydraulic Jacks depend on force generated by pressure
which is operating based on Pascal’s law. Its states that
the intensity of pressure at any point in a fluid at rest
are same in all direction.

3.  The shaft pushes on a crack that connects to a lifting pad, which is then
lifted horizontally A floor jack is a tool used to lift vehicles off the ground
in order to perform maintenance or repair work. In general, a floor jack
consists of a hydraulic cylinder connected to a base and a lifting arm. The
hydraulic cylinder is filled with hydraulic fluid and a pump moves the
fluid to the cylinder, causing the lifting arm to extend.
 Floor jacks operate on a principle of fluid mechanics and are designed to
provide a mechanical advantage when lifting heavy loads.

4.  The first floor jacks were manually operated scissor
jacks, which required a lot of effort to lift a
vehicle. However, with the invention of hydraulic
power, the floor jack evolved to become much
easier and more efficient to use. Today, floor jacks
come in various forms such as the trolley jack or
bottle jack and are commonly used in garages and
home workshops to lift vehicles so that maintenance
can be performed. Safety and performance
standards have been developed and implemented to
ensure that floor jacks remain safe to use.

5.  To perform a design analysis for a floor jack, you would
need to consider several factors such as the maximum
weight capacity that the jack will need to support, the
lifting mechanism, the materials used to construct the
jack, and the safety features.
 If the foundation of the home is in good shape, there is
also a type of floor jack that is basically a solid metal
pole with a flat end. The flat end is placed under the
house’s main beam and cranked tightly into place. This
solid post helps support the main joists and prevent
sagging. Without proper attention, sagging or rotting
floor joists will eventually collapse.

6. 1.2. objectives
1.2.1. General objectives
1.2.2. Specific objectives
1.2.1.General objectives
The objective of this report is to design a floor jack for small to medium-
sized vehicles that is easy to use and can lift vehicles to a height of 18
inches off the ground and to design modified compatible hydraulic floor jack
that can be used in every working place to raise part of the vehicle in order
to facilitate vehicle maintenance or break down repairs.

7. 1.2.2.Specific objectives
 Designing the jack to be durable and long-lasting to
withstand the stress and wear of frequent use.
 Ensuring the jack is easy to operate and maneuver
with features such as large wheels and ergonomic
handles.
 Optimizing the jack's lifting capacity and range to
accommodate various vehicle sizes and weights.
 Incorporating safety features such as overload
protection and locking mechanisms to maintain

8. Cont …
 To design base frame
 To design smaller frame
 To design ram cylinder
 To design plunger cylinder
 To design reservoir
 To design plastic pipe
 To design roller
 Drawing detail parts of the jack.

9. 1.3.Statement of the Problem
The problem with many floor jacks currently on the
market is that they are heavy, difficult to position
correctly, and can be dangerous to use if not used
properly. Additionally, many jacks are not able to
support vehicles with a high ground clearance.
Make sure that you are not overloading the jack which
means that do not try to lift the vehicle which weighs
more than the capacity the jack has. So if your jack is
not lifting the vehicle up first you need to check the
capacity of the jack.

10.  The low level of oil and oil beyond the fill line or overfilling of oil can
cause damage and prevent the jack from lifting weight i.e. decrease
its capacity of lifting weight and lower its capability.
 The oil reservoir or chamber located in the floor jack starts leaking oil
due to normal wear and tear.
 Overload valve is a safety feature for the floor jack which has the
warning “don’t open” so if it is turned on in wrong direction it causes
damage.
 If the wheels of the floor jack is not rolling properly then I recommend
you to use some lubricating oil on the wheels to reduce friction.

11. Cont…
 the main problems specifically:
 Jack will not lift a weight
 Floor jack leaks oil
 Overload valve was accidentally turned
 Wheels did not roll properly
 Cracking, bending or breaking of a floor jack
 Milky or foamy oil leakage
 Also over heat fairly quickly
 Has relatively slow speed and etc.

12. 1.4.Methods
.
e
search the current market and analyze the features
and drawbacks of existing jacks
Develop sev eral potential design concepts
Evaluate based on their feasibility, cost, weight, and ease
of use. Based on these evaluations
begin to create detailed specifications for each
component of the jack
Build a prototype of the jack and test it to ensure that it
meets our design requirements.
production

13.  To accomplish our design, we have used the
following methodologies.
 Problem identification: in this step, among the
problem which are challenges of the company, the
most and crucial problem will be selected.
 Data gathering: the data will be gathered or
collected by different means like; interview,
questionnaire, and from documents
 Analysis: in the analysis step, all the collected data
that are gathered from different source will be
analyzed in an organized manner.
 Design and simulation: in this procedure all the
parameters are interpreted and simulated to the
current design of the project.
 Conclusion and recommendation: General
conclusion about the project is given.

14. 1.5.Components of fluid power
In Hydraulic System there are six basic components.
1. A tank (reservoir) to hold the oil
2. A pump to force the oil through the system
3. A power source to drive the pump (electric, manual & others)
4. Valves to control oil direction, pressure, and flow
5. An actuator to convert the oil pressure into force (cylinders) or torque
(motors).
6. Piping, which carries the oil from one location to another

16. 1.5.Working principle
Figure:Working principle

17. A simple diagram of the hydraulic components in a hydraulic
floor jack:
 saddle/bearing pad (A),
 ram piston in ram cylinder (B),
 check valve between ram cylinder and plunger cylinder (C),
 plunger piston in plunger cylinder (D),
 handle (E),
 check valve between ram cylinder and reservoir (F), and
 reservoir (G)

18. o The above Figure is a simple diagram of the hydraulic system
in a hydraulic working principle of floor jack. .
 When the handle ( labeled E) moves the socket up, the
plunger piston ( labeled D) moves backward and siphons
hydraulic fluid from the reservoir ( labeled G) into the
plunger cylinder. When the handle moves the socket
down, the plunger piston moves forward and pushes the
hydraulic fluid into the ram cylinder ( labeled B).
 A check valve ( labeled C) stops hydraulic fluid from
flowing from the ram cylinder to the plunger cylinder.

19.  As a user pumps the handle, more and more fluid
builds up in the ram cylinder, building the pressure
and raising the bearing pad (labeled A).
 To release pressure in the ram cylinder, a user turns
the release valve, which opens the check valve
(labeled F) between the ram cylinder and the
reservoir. Hydraulic fluid flows back into the
reservoir, and the saddle lowers.

20. CHAPTER TWO
MATERIAL SELECTIONS
2.1.Materials
The correct component selection is important in
designing the project to avoid the misuse of
the materials or components used. In addition, in the
selection of components, the safety aspect
should also be emphasized as the project produced
must be used safely.
Tools and materials we used in this project are;
Tools are:
• Jack plain
• Chisel

21.  Materials are:
 Plastic syringe
 Small plastic bottle
 Steel balls
 Spring
 Gear shaft

22.  The choice of materials to design a floor jack depends
on various factors, such as the lifting capacity,
durability, weight, and price.
 Typically, high-quality floor jacks are made of durable
materials that can withstand the stress of lifting heavy
loads repeatedly. Steel is a commonly used material due
to its strength, toughness, and ability to resist wear and
corrosion.
 Some jacks may also incorporate Aluminium or other
lightweight materials to reduce the overall weight of
the jack, making it easier to move around.

23.  Additionally, the saddle and handle of the jack may feature materials
such as rubber or foam to provide a comfortable grip and prevent
slippage.
 Ultimately, the best material to design a floor jack will depend on the
specific needs and preferences of the user.
 The main aim of the project is the design, analysis and production of a
hydraulic floor crane having vertical arm motion of 360 degree,
horizontal arm motion up and down as well as movement of carrying
hook using pulley.

24. CHAPTER THREE
DESIGN ANALYSIS
Material selection and its Mechanical
Properties
It is the resistance offered by a material when
subjected to external loading.
So, stronger the material the greater the load it
can withstand.
• Depending upon the type of load applied the
strength can be tensile,
compressive, shear or torsional.
• Generally the jack made up of steel due to its
strength, weight, and cost.
• We select ATF (automatic transmission fluid) oil
the Selection of oil depend
on anti -wear additives and quality

25. Design Requirements:
 The design requirements for this floor jack include
the following:
 The jack must be able to lift vehicles of up to 4,500
lbs.
 The jack must have a lifting range of 6-18 inches off
the ground.
 The jack must be easy to position and use, with clear
instructions for operation.

26.  Load (W) = 5 ton (40,000N) ·
 OPERATING PRESSURE (p) = force/area = 40,000/ π/4*(25)
^2 = 81.48 * 106 N/m2
 Lift range (L) =3500 mm
 Man effort put on the handle (e) = 10 Kg
 Permissible tensile stress of mild steel (σ t) = 100 N/mm2
 No. of strokes for lifting load (n) = 90
 Permissible shear stress of mild steel (τ) = 20 N/mm2
 Permissible compressive stress of mild steel (σ c) = 20
N/mm2
 Permissible compressive stress of cast iron (σ CI) = 120
N/mm2
 Permissible shear stress of cast iron (τ CI) = 35 N/mm2

27. 3.2.Force Analysis
 Since the design should be done on the maximum loads, we
should specify the maximum load for the car.
3.2.1 Input Data
To calculate the force that applied on the smallest frame that
found on the top of five cylinders, we take the maximum
weight of the Toyota car.
M = 2000kg
g =9.8lm/s²
Force analysis of the overall parts is basic and important for
the stability and knowing the overall force transmitted to the
hydraulic jack.

28.  The load acting on the device is distributed to base support and assumed
to be uniform through the base. Now let as calculate the force acting on
the reaction of the weight at equilibrium. The force and momentum
summation = 0
∑ F = 0
∑ M = 0
There for the weight of the car (F) = m * g = 2000kg * 9.81m/s²
W = 19620 N

29.  w – f b – f a = 0 since ∑ f = 0 , ∑ m = 0
 Now let as determine the support force F a & F b
 Then to find f b let as consider the moment on a point of the front
point f a
 At f a , ∑ M = 0
W
 Anticlockwise momentum is assumed positive
 F b * L – f (L – b) = 0 fa
fb
 F b * L = f (L – b) L 240mm
 F b*0.14mm =19620 *(0.24 –0 .12)
 F b = 2354.4 Nm / 0.24mF b = 9810 N
120mm 120mm

30. The total force (∑ f =0) then w – f b –f a = 0
19620 N – 9810 – f a = 0
F a =19620 -9810
F a =9810N
There for the force acting 0n the base is stable,
Force of car (W) = force applied on a (f a) +force applied on b (f b)
19620 N = 9810 N + 9810 N
19620 N = 19620 N , There for the body is at equilibrium position

31.  The mass of smallest frame m = 4kg, so its force is:-
F frame = m*g = 4*9.81m/s²
= 39.24 N
 To calculate the force of the car that applied on the five cylindrical shells:-
We assume that the forces are equally distributed on the five cylinders
F on cylinder = F car + F f = 19620N + 39.24 N
= 19659.24 N………W1
 The mass of fluid tank with the full of fluid is 9kg, so
F flt = m F flt * g = 9kg*9.81m/s²
= 88.29 N……………W2
The mass of pumping cylinder is 2kg, so
Fpcyl = mpcyl *g = 2kg* 9.81m/s²
= 19.62 N
 The mass of pumping cylinder supporter is 3kg, so
Fp Cyl sup = m pcyl sup * g = 3kg*9.81
= 29.43N
19.62N + 29.43N = 49.05N ……….W3

32.  Therefore, to calculate the force that applied on the base frame,
we need to add the same of force

 of the car, circular tubes, the upper frame, thin cylinder (fluid
tank), pumping cylinder, and the

 pumping cylinder supporter.

 F on bfr = F car + Ff + F flt + Fpcyl + F pcyl sup

 = 19620N + 39.24N + 88.29N + 19.62N

 + 29.43N = 19796.58

33. Conclusion
The modification of this hydraulic floor jack is to help
elderly and handicapped even women to operate a jack
in an emergency.
By using this jack, it will save time and energy when
changing tire or doing maintenance on the side rode.
Thus, it can also reduce the possibility of getting
injuries such as backache. But the main part is about
the safety.
It is dangerous to be on the side rode so maintenance
needs to be done quickly to avoid from an unwanted

34.  This modified hydraulic floor Jack is safe to use after doing some
testing and calculation under some specification.
 The torque of the jack is strong enough to be able to lift a vehicle with
maximum load of 3-ton.
 This is more specifically for cars since the weight is around that point.
It is also very ergonomics which is the most fundamental concept of
designing an item.
 After spending a lot of time and energy for this project, we hope it will
be useful for people who is having trouble using jack especially in
emergency and safe