Project Report 2

A Project Report
On
Fabrication of Remote Controlled Forklift
Submitted By
Saurabh Verma 1609040029
Sandeep kumar Thakur 1609040026
Raj Singh 1609040021
Abhijit Singh 1509040005
Under the guidance

Mr. Amit Kumar Yadav
Mrs. Mukta Srivastava
IEC College of Engineering & Technology

Greater Noida (UP) India 201310
August 2019
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Contents
S.No. | Topic| Pg. No.
Contents ………………………………………………………………………….…2
List of figures ………………………………………………………………………22
1. Preamble …………………………………………………………………………....3
2. Nature of project...…………………………………………………………………..3
3. Preliminary investigation and objective……………….…………............................4
4. Preliminary objectives for the improvements……………………………………….4
5. Software/ Hardware tools ………..……………………………………....................4
6. Gantt Chart…………………………………………………………………………..5
References…………………………………………………………………………...5
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CHAPTER 1
INTRODUCTION
In general the forklift can be defined as a tool capable of lifting hundreds of kilograms of weight.
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 machines
that use levers and/or pulleys to lift significant weights. A fork lift one passes on the road may
look like a fairly modern invention, but these machines have actually been used for at least the
past 2000 years, if not longer. The Romans used forklifts to build huge monuments. Medieval
churches were constructed with them. Also, the Egyptians may have used them to create
pyramids. The modern version can be either simple or complex, and forklifts vary based on their
application. Fig. 1 To make the project work more realistic, much importance is given for
practical orientation, therefore a prototype module is constructed for the demonstration purpose.
This module simulates the real working system & based on this technology with slight changes
in the structure & motor ratings, the system can be converted for real applications. The method
of converting rotary to linear motion is implemented in the mechanism. The forklift is designed
to move in all directions including reverse direction also.
1.Preamble
Forklifts (also called lift trucks or fork trucks) are primarily used for lifting and transferring
heavy loads to stations or locations in warehouses, shops or construction sites. Usually there are
two forks in the front of a forklift (some type of forklifts have the forks on the side) that are used
to lift loads that may weigh up to thousands of pounds. These forks can be moved forward and
backward, and also up and down for lifting and moving cargo.
Figure1. Remote operated forklift[1]
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2.Nature of Project
It is a study about the forklifts and their functions. It also includes the designing and fabrication
of machine tool.
Figure 2. Proposed model[2]
2.1 Preliminary Investigation and Problem Identification[3]
 The Toyota Active Mast Function Controller senses and reacts to instability by restricting the
mast angle and speed according to the load's height and weight. This feature assists in
preventing forward tipping due to the reduction in lift capacity caused by the mast tilting
function.
 Over speed prevents side tripping.
 Generally 75% of side tripping occurs when the fork lift is empty.
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Fig. 4. Side tripping [5]
Fig.5 misbalance[6]
2.2Preliminary Objectives for the Improvements[4]

 The first solution is introducing of SAS system of active stability.
 Locking the pivotal rear axle to prevent lateral tripping over.
 This could lead the safety of the driver and increase the productivity.
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3. Component
 Base (Chassis)
 Pulley
 Bearing
 Motor Remote controlled system
 Motor
 Shaft
 Slider
 Bettery
3.1 Base (CHASIS)

The chassis is fabricated from Plywood sheet. This is done for ease of fabrication, and to reduce
the overall weight. The chassis was designed to take a static load. The flange which holds the
motor was designed using Aluminium and is bolted to the chassis. So that the driving motors can
easily accommodate below the chassis. The chassis incorporates hole for attaching front globe
wheel, and also for attaching the lift structure.
3.2 Pulley
The pulleys are used to transmit power from one point to another by means of belts or ropes.
Since the velocity ratio is the inverse ratio of the diameter of the driving and driven pulleys,
therefore the pulley diameter should be carefully selected in order to have a desired velocity
ratio. The pulley must be in perfect alignment in order to allow the belt or rope to travel in a line
normal to the pulley faces.
3.3 Bearing
Bearing are mechanical assemblies that consist of rolling elements and usually inner and outer
races which are used for rotating or linear shaft applications, and there are several different types
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of bearings, including ball and roller bearings, linear bearings, as well as mounted versions that
may use either rolling element bearings or plain bearings.
3.4 Remote Controlled System

The forklift is equipped with manual keys. By activating these keys manually, all the movements
can be created in the forklift. All these keys are directly interfaced with electrical bridge circuit
at input side, one end of all the keys are shorted together and connected to the ground. When any
key is pressed, biased current is transmitted to the next node and follows, based on this bias the
circuit drives the motor
3.5 Motor
An electric motor is a machine which converts electric energy into mechanical energy. Its action
is based on the principle that when a current carrying conductor is placed in magnetic field, it
experiences a mechanical force whose direction is given Fleming’s Left Hand Rule.
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Figure 6.Motor
3.6 Shaft
A shaft is a rotating machine element which is used to transmit power from one place to another.
The power is delivered to the shaft by some tangential force and the resultant torque set up with
the shaft permits the power to be transmitted to various machines linked up to the shaft. In order
to transfer the power from one shaft to another, the various members such as pulleys, gears etc
are mounted on it. These members along with the forces exerted upon them causes the shaft
tobending. In other words, we may say that a shaft is used for the transmission of torque and
bending moment. The various members are mounted on the shaft by means of keys or splines.
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3.7 Slider
It’s a rectangular plate which is held between two vertical channels of metal which are free to
slide up and down to lift and lower the weight/load up to a desired limit with the help of rope
which is connected to the DC Motor by means of Shaft and Bevel gears.
3.8 Battery
It supplies power to motor and gear box which runs the wheel and barrel.
4. Material
 Plywood
A type of strong thin wooden board consisting of two or more layers glued and pressed
together with the direction of the grain alternating
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 Mild Steel
Steel which contains only a small percentage of carbon and is strong and easily worked
but not readily tempered or hardened.
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A Project Report

Under the guidance

IEC College of Engineering & Technology

Figure1. Remote operated forklift[1]

Figure 2. Proposed model[2]

2.1 Preliminary Investigation and Problem Identification[3]

2.2Preliminary Objectives for the Improvements[4]

3.1 Base (CHASIS)

3.4 Remote Controlled System

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