Design and Manufacturing of Automatic Multipoint Spanner For Maruti 800

DESIGN AND MANUFACTURING OF AUTOMATIC
MULTIPOINT SPANNER FOR MARUTI 800

A PROJECT REPORT
Submitted By:-
DHVANIL Y. SUTHAR (130903119083)
DIPAK N. RAJPUT (130903119075)
JAYRAJSINH J. RATOD (130903119076)
In fulfilment for the award of the degree

Of
BACHELOR OF ENGINEERING
In
MECHANICAL
Tatva Institute Of Technological Studies, Modasa
Gujarat Technological University, Ahmadabad

CERTIFICATE
Date….………..
This is to certify that the dissertation entitled “DESIGN AND

MANUFACTURING OF AUTOMATIC MULTIPOINT SPANNER FOR
MARUTI 800. ” has been carried out by DIPAK RAJPUT, DHVANIL SUTHAR
& JAYRAJSINH RATHOD under our guidance in fulfillment of the degree of
Bachelor of Engineering in Mechanical (7th semester) of Gujarat Technological
University, Ahmadabad during the academic year 2015-16.
Internal Guide: Head of the department:
Mr. Savankumar V. Varma Mr. Mohit B. Diwan
Department of Mechanical Department of Mechanical
TITS, MODASA TITS, MODASA

ACKNOWLEDGEMENT
We feel in great in presenting the report of our project “Design and

Manufacturing of Automatic Multipoint Spanner for Maruti800” which finds
application in much modern generation equipment and future new system, this
project is done in partial fulfillment of B.E. (bachelor in mechanical engineering)
course. I would like to take this opportunity to thank all those whose supported me
to achieve this milestone.
We wish to express our sincere gratitude and thanks to our guide professor.
During our whole project work for his inspiration give to us and give some
innovative ideas about our project. He was greatly helpful to us by solving all our
queries and difficulties. We are also thankful to our head of the department of
mechanical engineering.
I would like to express my sincere regards to Prof.Savan v. varma for his

constant motivation and support for entire duration for this project. It is my
privilege and honor to have worked under his supervision.
The co operation and guidance extended by the Head of Department Prof.

Mohit B. Diwan and the faculties have also been very conductive to the
preparation of this product.
We are thankful to and all out lecturers who showered upon there help and
guidance during the project work and also our friends who always ready to help.
ABSTRACT
Spanner is very conventional tool for any mechanical applications. So it is a very

essential part of the automobile industries. Where there is a need of speedy and
accurate work. In most of the industries the multi point spanner is necessary to
reduce the cost and handle the situations. Here, in this project report we have
designed and explained the whole design criteria of one of the auto mobile
equipment i.e. “AUTOMATIC MULTI POINT SPANNER”. From it one can
understand the design procedure of the spanner and the analysis of its mechanism.
When a tire of a 4 wheel is punctured it has to be removed with ordinary spanner
which is tedious and time consuming. With this spanner you can simply open all
of the 4 bolts simultaneously by single effort (e.g., power supply). This saves time
and so as efforts.
SELF-DECLARATION BY STUDENTS OF UDP
We,
Name Branch Enrollment No.

Dhvanil suthar Mechanical 130903119083
Jayrajsinh rathod Mechanical 130903119076
Dipak rajput Mechanical 130903119075
Enrolled at TATVA INSTITUT OF TECHNOLOGICAL STUDIES, MODASA hereby

certify and declare the following:
1. We have defined our project based on inputs at DESIGN AND MANUFATURING OF

AUTOMATIC MULTIPOINT SPANNER FOR MARUTI800 and each of us will make
significant efforts to make attempt to solve the problem .we will attempt the project work at my
college and consistent monitoring of SAVAN V. VARMA
2. The project work is not copied from any done any other projects. (Same project can be done
in different ways but it has special and different from other, because it has modification,
innovation, and use of some latest technology)
3. We understand and accept that he above declaration if found to be untrue, it can result in
punishment/cancellation of project definition to me/we including failure in the subject of project
work.
Name Contact No. Sign

JAYRAJSINH RATHOD 9033712876
DIPAK RAJPUT 7405551280
DHVANIL SUTHAR 8460068357
Date…………… Place……………
TABLE OF CONTENT
Acknowledgement
Abstract
List of figures
List of tables
Chapter: 1 Introduction…………………………………………………….…1
Chapter: 2 Literature review……………………………………………….....3
Chapter: 3 Project planning…………………………………………………..4
Chapter: 4 Market survey …………………………………………………....5
Chapter: 5 Detail of project…………………………………………………. .6
Chapter: 6 Design calculations……………………………………………….24
Chapter: 7 Detail drawing…………………………………………………....33
Chapter: 8 Assembly drawing ……………………………………………....35
Conclusion…………...………………………………………………………..39
References……………………………….……………………………………40
LIST OF FIGURES
Figure 1: Working principle of automatic spanner …………………….………...........................9
Figure 2: 4-way lug wrench …………………………………………………………………….14
Figure 3: spark plug wrench ………………………………………………….………………...15
Figure 4: ratcheting box wrench ………………………………………………………………..15
Figure 5: impact wrench, impact driver ……………………………………………….………..16
Figure 6: combination wrench ………………………………………………………………….17
Figure 7: socket wrench ………………………………………………………………………...17
Figure 8: Methodology…………………………………………………….................................18
Figure 9: Outline for developing the mechanic…………………………………………………25
Figure 10: The developed mechanism ………………………………………………………….25
Figure 11: Design of gear……………………………………………………….........................28
Figure 12: Design of pinion…………………………………………………….….....................29
Figure 13: Central gear shaft………………………………………………………….…...........30
Figure 14: Pinion shaft …………………………………………………….……………………31
Figure 15: Central shaft key…………………………………………………….….....................31
Figure 16: Pinion shaft key …………………………………………………………………......31
Figure 17: Plates ………………………………………………………………....……………32
Figure 18: Socket ……………………………………………………………..………………..32
Figure 19: Gear ……………………………………………………………….………………..33

Figure 20: Pinion …………………………………………………………….…………………33
Figure 21: Shaft ………………………………………………………………….......................33
Figure 22: Pinion Shaft …………………………………………………………………………34
Figure 23: Key ……………………………………………………………..…….......................34
Figure 24: Bushes and Plates ………………………………………………..….........................34
Figure 25: Sockets ……………………………………………………………….……………..34
Figure 26: Assembly drawing ……………………………………………………......................35
Figure 27: Assembly drawing ………………………………………………………………….35
Figure 28: Working model …………………………………………………………………….36
LIST OF TABLES
Table 1: Gears ……………………………………………………………...…………………...20
Table 2: Shafts …………………………………………………………………..……………...21
Table 3: Guide Plate ………………………………………………………...………………….21
Table 4: Parameter ……………………………………………………………….......................28

CHAPTER: 1
INTRODUCTION
General
The process of project work depends on new creation, intelligence, skills, creativity, energy
of group of student and to know about next generation requirement of material & gadgets.
The purpose of providing project work is to solve problems and to introduce you to the
procedures of solution of problem.
By doing this you improve confidence to take decision and taking problems project work will
integrate.
OBJECTIVE OF PROJECT
• The following are the main objective of project
 A student can develop his mind to words engineering filed and they come to know
various manufacturing of various parts.
 Each can develop his ability to plan a work and take perfect decision.
 It develops confidence and creative solution of thinking.
 It helps to creative solution of problem.
 Students can apply his knowledge in practical situation regarding to the project.
 Maintain level of problem while clearing with engineering solution
DESIGN AND MANUFACTURING OF AUTOMATIC MULTIPOINT SPANNER FOR MARUTI 800.

Page 1
CHARACTERISTICS OF PROJECT
• The following are the main characteristic of the Project
 OBJECTIVE -A project should have specific objective to be filled.
 TIME PERIOD - A project it has be completed in given time period.
 TERM WORK - Term work includes all the aspects of the term work.
 FEATURE - A project should have great feature.
 MADE TO ORDER - A project should have servile of ingredients in term of

Technology.
 SUCCESIVE - More and more positive think of the project and known at each stage
of project work.
 RISK - Projects has certain amount involved in its performance depend upon
construction, Quality and Mechanisms.

Page 2
CHAPTER: 2
LITERATURE
RIVIEW
What is literature?
The quest to discover a definition for "literature" is a road that is much travelled, though the
point of arrival, if ever reached, is seldom satisfactory. Most attempted definitions are broad
and vague, and they inevitably change over time. In fact, the only thing that is certain about
defining literature is that the definition will change. Concepts of what is literature change
over time as well.
 Tarachand G. Lokhande, Ashwin S.

Chatpalliwa
Conventional spanner is required to open the nuts of the wheel assembly of Maruti 800. for
opening all the four nuts, it requires separate attention and time. For opening each nut, then
get up and apply the initial torque with his foot, and after that, he has to rotate the spanner
with his hands to open the nut. And this same procedure has to be repeated 4 times. In this
process, fatigue to the operator is more, end and it is also time consuming. Hence, with all
these perspectives in mind, we thought of an innovative mechanism to address these issues.
 John Wilkinson and Henry Maudsley (International

Journal of Modern Engineering Research
 A wrench is also called a spanner. It is a tool used to provide grip and mechanical
advantage in applying torque to turn objects usually rotary fasteners, such as nuts and
bolts or keep them from turning.
 In British English, spanner is the standard term. The most common shapes are called
open-ended spanner and ring spanner.

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CHAPTER 3
PROJECT PLANNING
STEPS OF PROJECT PLANNING
Before starting any project its planning is carried out, planning of a project is largely
depend upon its planning a project.
The success of the project depends upon the perfect and efficient planning of the activities.
 Selection of project
 Market survey
 Manufacturing feasibility.
 Raw Material requirement.
 Design and drawing

 Manufacturing process.
 Operational planning
 Material Handling
 Costing
 Method of time Studies.
 Testing of project
 Market response of project.

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CHAPTER 4
MARKET SURVEY
MARKET SURVEY
 You need to check yourself a market survey of the product selected by you.
 Market prospect. A comprehension market study is must be specific advantage of

such a study are.
 It enables you to evaluate viability of an enterprise by arcing at a year estimate of

seals.
 It makes it possible for you to estimate scale and utilization of install capacity with
reference propose enterprise.
 You can judge weather proposed capacity is on higher and lower size.
 It provident a preliminary input for the marketing strategy and process formulation or
the enterprise (A market program is a set decision refried in a respect of various
market related to issued it influents the market performance of an enterprise.)
 Market survey is usually focused on gross market demands present and future. It
Typically highlights the gaps between expected market demand and supply in respect
offer given product. Such a gap could be positive (demand exceed supply) and
therefore favourable. The gap could be negative a favourable gap is does not guaranty
market success for an enterprise a market success is and between of favourable
demand supplies gap as well effective market program.

Page 5
CHAPTER 5
DETAILS
Definition
Concept
Working Principle
Working
Requirements
Future Scopes
Parts of AMPS

Page 6
Definition of AMPS
Whenever we got our vehicle punctured then we have to remove the wheel
from car and for that we need a spanner of specified diameter. Then we remove all of
their nut’s “one by one”. This required so much of human effort as well as time. If we
consider FORMULA 1 racing game so we know that time is very important factor to be
consider. In these type of situation the cars runs at very high speed. At that time tire gets
heated because of friction. This causes the expansion of gases inside the tires that they may
lead to unstable and out of control from driver that may cause harmful accidents. That’s why
they change tires at after particular time or kilometer. So that time, TIME is most important
factor.
Tire changing is really a boring and seedy job. Now in this project we tried to make
this work easy which doesn’t take much effort and it’s also not boring. Before we start the
procedure make sure that we have some other primary equipments.
• A Jack (Hydraulic or screw jack)

• A Usable Spare Wheel.
• Lug Bolt.
• Lug Spanner or Spanner Set.

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THE CONCEPT OF AUTOMATIC MULTI POINT
SPANNER
If the object you’re working on has in held in place with multiple fasteners, never tighten
one fastener to full torque before doing up the rest. Instead, torque them up evenly, working
your way back and forth across the object. This applies to wheel nuts, cylinder head bolts,
tappet cover bolts – anywhere there’re multiple fasteners used to hold something in place.
and the reason? You want the object to ‘bed down’ evenly, not end up cocked on one side
In India and other developing countries, the above stated hydraulic and pneumatic tools
are turn out to be very costly. In India, you find many tyre changing shops on roadsides
which are run by people as a source of livelihood. car manufactures provide a single point
spanner to open the nuts individually for them cars.
Spanner is required to open the nuts of the wheel assembly of Maruti 800. for opening all
the four nuts individually, it requires separate attention and time. For opening each nut, then
get up and apply the initial torque with his foot or hand, and after that, he has to rotate the
spanner with his hands to open the nut otherwise close. And this same procedure has to be
repeated 4 times. It is time consuming.
We thought of making automatic multipoint spanner which opens all the four nuts of a
wheel simultaneously together. We devised gear mechanism which consists of a central gear
and four meshing pinion gears. These gears are assemble with equal diameter. A lever is
mounted on the central gear, which meshes with 4 gears. When torque is apply on this central
lever, it will rotate the central gear, which in turn will rotate the pinion gears. The shafts on
which these pinion gears rotate are attached to sockets which fit into the nuts of the wheels.
Once these pinion gear shafts rotate, they will rotate the sockets which open the nuts which
have fastened the wheel of the vehicle.

Page 8
WORKING PRINCIPLE OF THE SPANNER
The spanners are working on a basic principle of Newton. The principle is state that: - “moment
is equal to the product of force and distance.” The principle is illustrated in the figure given as
follows:-
Figure no. 1
WORKING PRINCIPLE OF THE SPANNER
So, the moment M = F×D

Where,
M = moment required for open nut & bolt.
F = Force applied by the hand.
D = Distance between hand and the centre line of nut.

Page 9
PRINCIPLE OF MECHANISM
The project has to give the positive & negative potential to the spanner. If we
push the corresponding switch for forward rotation, it helps to fix the nut, or
else if we push the corresponding switch for reverse rotation, the
given polarity will be changed oppositely and it helps to remove the nut. The
spanner can be operated according to the operator’s requirement. The electric
power can be given by the battery and also use of pneumatic gun . The operator
should lift the model and place at the appropriate place to tighten or remove the
nut.
DEVELPOMENT OF MECHANISM
(A)Arrangement of gear pinions:
The pinions are arranged at a pitch circle diameter of 116mm and 90 degrees apart from each
other, meshing with the main gear.
(B)Arrangement of gear and pinions with guiding plates:
Spanners, main shaft and lever: The gears and pinions are fitted between the two guiding
plates.

Page 10
WORKING OF THE MULTIPOINT AUTOMATIC
SPANNER
The spanner has a simple gear arrangement. The gear

Pinion ratio is 1.11:1.
The steps involving in working are as follows:
First of all engaging the spanner on the wheel, the wheel must be lifted on the jack,
because the total weight of the wheel disc is transferred on the spanner which increases the
torque required to open the nuts.
Lift this automatic spanner and place it onto the four nuts for opening or closing, so that
its sockets come in alignment with the nuts.
Fix the automatic spanner on the nut.
With the help of the lever, electric motor or pneumatic gun, which has a groove at the end,
and gets fitted in the main part of the gear shaft, and then, torque is applied on this spanner.
The clockwise motion of the shaft of gear rotates the pinion anticlockwise so that the nut
gets open and vice versa.
REQUIREMENTS OF THE AUTOMATIC SPANNER
Proper oiling to the bushes to reduce coefficient of friction.
Power greasing to gear and pinions to reduce noise due to friction.

Page 11
Torque must be applied after matching of the socket nuts.
The length of the bolt with wheel discs is same so that all the nuts can be tightened evenly.
Electric power source require when using electric motor.
Require pneumatic gun when fast exchange fatly tire change

Page 12
FUTURE SCOPES
We have spent most of the last year working with the manufacturing of cars and F1 team to
transition Google’s advertising backend from MySQL to Spanner. We are actively improving
its monitoring and support tools, as well as tuning its performance. In addition, we have been
working on improving the functionality and performance of our backup/restore system. We
are currently implementing the Spanner schema language, automatic maintenance of
secondary indices, and fully automated. Longer term, there are a couple of features that we
plan to investigate. Optimistically doing reads in parallel may be a valuable strategy to
pursue, but initial experiments have indicated that the right implementation is non-trivial.
Given that we expect many applications to replicate their data across datacenters that are
relatively close to each other, True Time may noticeably affect performance. We see no
insurmountable obstacle to reducing below 1ms. Time-master-query intervals can be reduced,
and better clock crystals are relatively cheap. Time-master query latency could be reduced
with improved networking technology, or possibly even avoided through alternate time-
distribution technology. Finally, there are obvious areas for improvement. Although Spanner
is scalable in the number of nodes, the node-local data structures have relatively poor
performance, because they were designed for simple key-value accesses. Second, moving
data automatically between datacenters in response to changes in client load has long been a
goal of ours, but to make that goal effective, we would also need the ability to move client-
application processes between datacenters in an automated, coordinated fashion.
And other future scopes are….

Automation of spanner
Use of better manufacturing process
Use of better materials

Page 13
TYPES OF SPANNER
American name: - 4-way lug wrench wheel lug cross wrench cross rim wrench
spider wrench
British name: - wheel brace
Figure no.2
Description:- A socket wrench used to turn lug nuts on automobile wheels.

Page 14
American name:- spark plug wrench
British name:- box spanner, tube spanner, spark plug spanner
Figure no.3
Description:- A tube with six-sided sockets on both ends. It is turned with a short
length of rod (Tommy bar or T bar) inserted through two holes in the middle of the tube.
American name:- ratcheting box wrench

British name:- ratcheting ring spanner
Figure no.4
Description:- A type of ring spanner, or box wrench, whose end section ratchets.
Ratcheting can be reversed by flipping over the wrench, or by activating a reversing lever on
the wrench. This type of wrench combines compact design of a box wrench, with the utility
and quickness of use of a ratchet wrench. A variety of ratcheting mechanisms are used, from
simple pawls to more complex captured rollers, with the latter being more compact,
smoother, but also more expensive to manufacture.

Page 15
American name:- impact wrench, impact driver
British name:- pneumatic spanner, windy spanner, rattle gun, impact driver, Windy
gun
Figure no.5
Description:- A powered wrench which delivers quick, repeated impulses of torque.

Typically powered by air, but can also be electric. Most people have heard its familiar rap-
rap-rap noise while being used in an auto repair shop. Although many professionals use them
to tighten lug nuts on vehicle wheels, do-it-yourselfers should use a torque wrench since an
impact wrench can often over-torque and damage the threads on lug nuts and wheel studs.
Impact wrenches are great for loosening stubborn, difficult-to-remove nuts and bolts.

Page 16
American name: - combination wrench
British name:- combination spanner, open-ring spanner
Figure no.6
Description:- A double-ended tool with one end being like an open-end wrench or
open-ended spanner, and the other end being like a box-end wrench or ring spanner. Both
ends generally fit the same size of bolt.
American name:- socket wrench

British name:- socket wrench, socket spanner
Figure no.7
Description:- A hollow cylinder that fits over one end of a nut or bolt head. It may
include a handle, if it does not then it is often just referred to as a socket and is usually used
with various drive tools to make it a wrench or spanner such as a ratchet handle, a tee bar bar
or a knuckle bar.

Page 17
PARTS OF AUTOMATIC MULTIPOINT SPANNER
Gear and pinion
Shaft
Lever
Bushes and plates
Sockets
Pneumatic gun
Electric power source
Compressor
MANUFACTURING METHOLOGY
The design of the vehicle all-wheel-nuts remover tool is performed by commercial computer
aided design (CAD) software as shown by Figure.
Figure no.8

Page 18
Several static load analyses are also performed in order to find the safety factor of the design.
Theoretical calculation analysis is carried out with the purpose of validation. The force
required for removing four numbers of nuts is,
F = 4τ / (lRG)
Where, F is the applied force, τ is the torque required to remove one nut, l is the length of
level and RG is the gear ratio of central gear and driven gears of the tool.
In the fabrication of VAWNR tool, two processes are performed; milling and fitting. Since
the gears are not available in the market, custom designed gears need precision milling and
fitting processes. Once the tool is ready, an experiment is performed with the intention to find
the time required to remove the nuts. This result is then compared with the time required
using ordinary L-shaped wrench. Experiment using impact wrench is also performed.

Page 19
GEARS
Name of Raw Operation Machine Measuring Time Remarks

part material sequence tools s tools (min
size (mm
Dia. 54 Blank Lathe Vernier 360 4 nos.

(a) Pinion Width = preparation Lathe scale
[EN 8] 20 Centering Milling Dial gauge
Indexing Milling
Gear
cutting
(b)Gear DIA. 60 Blank Lathe Vernier 180 1 no.

[EN 8] T = 20 preparation Lathe scale
Centering Milling Dial gauge
Indexing Milling
Gear
cutting
Table no.1

Page 20
SHAFTS

part material sequence tools tools (min)
size (mm)
Main shaft Dia. 25 Turning Lathe Vernier 30 1 no.

scale & dial
[EN 8] 1 = 100 gauge
Facing Lathe
Pinion Dia. 16 Turning Lathe Vernier 120 4 no.

shaft scale & dial
1 = 78 gauge
Facing Lathe
Table no.2
Guide plate

part material sequence tools tools (min)
size (mm)
Guide Dia. Turning Lathe Dial gauge 15 2 nos.

plates
[M.S] 190
t=6 Indexing Milling Vernier

scale
Drilling Drill 30
Table no.3

Page 21
limitations of multipoint Automatic Spanner:
 When torque is given manually, there is limitation for application of torque which
depends upon the capacity of the man.
 As the guide plates are heavy. so difficult to handle.
 Require continuous lubrication for smoothly work.
 It is used only for Maruti800.
 If any one of the four nuts is tightened earlier then the rest, remaining nuts cannot be
tight further by it.
 It is only use for maruti800 so it can not use for all kinds of four wheelers but by
modifying the design one can make it applicable for other four wheelers too.
 Due to use of pneumatic gun or motor power source is require.
ADVANTAGES
 This spanner is use to by small effort opening or closing the wheel bolt and
changes the wheel in minimum time.
 This spanner is save our money, and time.
 In this spanner four bolts are open and closed at a time together.
 Time saving because time required for opening 4 nuts by auto automatic spanner
simulationaly.
 Equal tightening of the nuts is possible so that the wheel geometry is maintained.
Also, the fatigue is less as force required to open the 4 nuts by mechanical spanner
is near about same as conventional spanner.
Automatic multipoint spanner we observe that the opening of nuts of wheel can
done faster and easily as compare to conventional spanner.

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DISADVANTAGES
 Cost of this spanner is high.
 Use of this spanner Only For One Car.
 Doesn’t Use For Different Car Wheel.
 Due to Manually Operated time consume is more compare to use of pneumatic gun.
 In This Spanner High Quality Gear’s And Material Are require for best work.
APPLICATION
 In auto mobile industries.
 This spanner is use in car racing competition.
 Aerospace
 Side road garage

Page 23
CHAPTER: 6
DESIGN CALCULATION OF AUTOMATIC
MULTIPOINT
SPANNER FOR MARUTI 800
DESIGN OF AUTOMATIC MULTIPOINT SPANNER
The basic fundamentals of law of gearing have to be followed in designing the bevel gears.
The Fundamental law of gearing states that, “For a pair of gear to transmit constant angular
velocity ratio, the tooth profiles of these mating gears must be designed in such a way that the
common normal (line n-n) or the line of action passes through a fixed point, or also known as
the pitch point, on the line of centers.”
The various parts of the mechanical multi point spanner are as follows:-
 Design of gear and pinion.
 Design of shaft.
 Design of lever.
 Design of bushes & plates.
 Design of sockets.

Page 24
DESIGN OF GEAR AND PINION
First of all, we find pitch circle diameter of pinion gear and central gear determined from the
wheel catalogue of maruti 800, we get the pitch circle diameter of 4 studs as 114 mm.
we get the tightening torque for nut as 650 kg.cm (=65000 N.mm)
Figure no.9
Figure no.10

Page 25
For design of gear given parameters are:
 m = Module in mm
 D p = pitch circle diameter of the pinion.
 D g = pitch circle diameter of the gear.
 T g = no of teeth on central gear.
 T p = no of teeth on pinion.
 T g = torque acting on central gear.
 T p = torque acting on pinion.
Both the gears are made from the same material, Pinion is to be considered for the design.
We take gear ratio of 1:1, and get the diameter of gear and pinions as 57 mm each. Minimum
no. of teeth on the gear as 18 ( for 20 degree full length involutes) to avoid interference.
Now, use formula for it,
m=Dp/Tp
m = 57 / 18
= 3.166.
Module value is not standard. Hence, use data book of design, Select a standard module
I.e. m = 3.
Actual diameters of the pinion and the gear is..
Dp=m×Tp
= 3 × 18

Page 26
= 54 mm
Dg = m × T g
= 3 × 20
= 60 mm
Note: here, we take no. of teeth on the gear as 20.
Therefore, we get the real gear ratio
G=Dg/Dp
G = 60 / 54
= 1.11 : 1
Hence, we are get the final gear ratio of 1.11 :1
D g = 60 mm
D p = 54 mm
T g = 20 teeth
T p = 18 teeth.

Page 27
The following information can be calculated using design data book:
Particulars Proportion Value (mm)

Addendum 1*m 3
Dedendum 1.25*m 3.75
Work depth 2*m 6
Min. total depth 2.25*m 6.75
Tooth thickness 1.5708*m 4.7124
Clearance 0.25*m 0.75
Root fillet 0.4*m 1.2
Face width 6*m 20
Table no.4
Figure no.11

Page 28
Figure no.12
CALCULATION OF FORCE ACTING ON GEARS AND SHAFT

Torque required for remove one nut = 65 Nm
Total torque required for remove all 4 nuts = 4 × 65
= 260 Nm
T p = 2, 60,000 N.mm
Hence, F = Total force acting on the central gear:
Tp=F×rp
F=Tp/rp
= 260/0.27
=962.966 N
Torque acting on the central gear:

Page 29
Tg=F×rg
= 962.96 × 0.3
= 288.88 N m
= 300 N m (say).
DESIGN OF CENTRAL SHAFT

The design of the central shaft is done on the basis on the stiffness and rigidity and in it
the specially for the twisting moment acting on the shaft.
Figure no.13
Now, Torque acting on the shaft,
T = π/16 Xd³T × k w f
For the material used (EN8),
K w f = 0.75
T = 45 N/mm²
Put this values in above equation, we get
300 × 10³ = π/16 x45d³ (0.75)
dg = 25 mm

Page 30
DESIGN OF PINION SHAFT
Figure no.14
T = π/16 Xd³T × k w f
65000 = π/16 x45d³ (0.75)
d = 15.4 mm
= 16 m
DESIN OF KEY
Figure no.15 Figure no.16
According to standard design data book,
For shaft diameter up to 17 mm,
Key should be w = 6 mm
t = 6 mm
Shaft diameter, the key should be
W = 8 mm, t = 7 mm
Page 31
DESIGN OF BUSHES AND PLATES
We have taken plate of diameter of 190 mm and thickness t = 6 mm.
The detailed drawing showing in fig.
Figure no.17
The bushes are purchased as readymade available in market the market. Design of
diameter 15 mm and the thickness t = 5 mm.
The spacers are fitted between the plates over the bolts. We used M8 type to fasten.
On the bolts, we have put brass spacers between the plates so that there is no friction between
the plates and gears.
SOCKETS
The sockets are used as grip for nuts of the wheel of car. And they easy operation for spanner.
Figure no.18
Each of the four pinion shafts have holes drilled, then four bolts of square headed type have
been fitted and welded.
sockets are fit in to the hexagonal nut in the wheels of Maruti 800.

Page 32
CHAPTER 7
DETAIL DRAWING
DETAIL DRAWING OF AUTOMATIC MULTIPOINT
SPANNER FOR MARUTI 800
GEAR
Figure no.19
PINION
Figure no.20
SHAFT
Figure no.21
Page 33
PINION SHAFT
Figure no.22
KEY
Figure no.23
BUSHES AND PLATES
Figure no.24
SOCKET
Figure no.25

Page 34
CHAPTER 8
ASSEMBLY DRAWING
ASSEMBLY OF AUTOMATIC MULTIPOINT SPANNER FOR
MARUTI 800
Figure no.26
Figure no.27

Page 35
Figure no.28
COSTING
It is the determination of actual cost of various department. It may also be defined as a
system. Various departments to determine the cost of manufacturing product.
AIM OF COSTING
 To determine the cost of each part.

 To determine the cost of each article operations to keep control our workers wages.
 To provide information to ascertain the selling price of product.
 To know information about waste.
 For reducing total cost of manufacturing.
PROCEDURE OF COSTING
 Direct material cost.
 Indirect material cost.
 Direct labours cost.
 Indirect labour cost.
 Direct expense.
 Indirect expense

Page 36
CONCLUSION
This invention reduces the time consumed in removing the lug nuts. In conventional method,
certain torque has to be applied to remove a single lug nut. In this invention, the torque
applied for removing/tightening of one lug nut is adequate for removing/tightening of all the
lug nuts in the wheel of maruti 800. So the process of replacement of the wheels can be done
so faster and it reduces the time. This device can be operated manually, use of air gun and
electric motor. In this mechanism, a sun and planet gear system is used. Sun gear is smallest
gear and planetary gears are placed exactly in the position of the lug nuts in the pitch circle
diameter according to the number of lug nuts. Pitch circle diameter is the diameter of the
circle in which lug nuts are positioned.

Page 37
REFERENCES
[1] A. R. Abd Aziz “Improvement and Optimization of Tire Nut Removal with 114 PCD”.
Universiti Malaysia Pahang, Thesis Degree, 2008.
[2] M. F. Abd Rahim “Design, Development and Fabrication of Tyre Lug Wrench”.
Universiti Teknikal Malaysia Melaka (UTeM), Thesis Degree, 2007.
[3] R. Abdul Rahman, C. A. Che Ismail and M. Y. Abdullah “Mechanik Mesin”. Universiti
Teknologi Malaysia Publisher, 2003.
[4] V. Sarkar “Mechanics of Machines”. Tata McGraw-Hill, 2004.
[5] E. Oberg, F. D. Jones, H. L. Horton and H. H. Ryffel (2008) “Machinery’s Handbook 28th
Edition”. Industrial Press, 2008.
[6] Different tools, Source: http://www.williamtool.com.
[7] Dr. P.C. Sharma- A text book of production technology-1996
[8] Fasteners, Source: http://www.laytonfasteners.com.
[9] Gordon R. Pennock and Jeremiah J. Alwerdt, “Duality between the kinematics of gear
trains and the statics of beam systems”, Science direct journal,
Volume 42, page 1527-1546
[10] Hiroyuki Kato, Ken Iwanami, Hiroshi Arai, Koji Asanotells, “Running safety and
comfort”, International journal, Volume 28, page 541-578
[11] Ligang Yao Jian S. Dai Guowu and Yingjie, “Meshing characteristics of toroidal drive”,
Science direct journal, Volume 47, page 827-854
[12] Nuts and bolts standards, Source: http://www.nutsandboltsstandings.com.
[13] PSG design data book, Second edition-1999
[13] Shigley.J.E and Mischke C.R. - Mechanical Engineering Design-2008
[14] Stefan Staicu, “Inverse dynamics of a planetary gear train for robotics”, Research gate
journal, Volume 47, page 728-767

Page 38

Design and Manufacturing of Automatic Multipoint Spanner For Maruti 800

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DESIGN AND MANUFACTURING OF AUTOMATIC

MULTIPOINT SPANNER FOR MARUTI 800

DHVANIL Y. SUTHAR (130903119083)

DIPAK N. RAJPUT (130903119075)

JAYRAJSINH J. RATOD (130903119076)

In fulfilment for the award of the degree

Tatva Institute Of Technological Studies, Modasa

Gujarat Technological University, Ahmadabad

This is to certify that the dissertation entitled “DESIGN AND

Internal Guide: Head of the department:

Mr. Savankumar V. Varma Mr. Mohit B. Diwan

Department of Mechanical Department of Mechanical

TITS, MODASA TITS, MODASA

We feel in great in presenting the report of our project “Design and

I would like to express my sincere regards to Prof.Savan v. varma for his

The co operation and guidance extended by the Head of Department Prof.

Spanner is very conventional tool for any mechanical applications. So it is a very

Name Branch Enrollment No.

Enrolled at TATVA INSTITUT OF TECHNOLOGICAL STUDIES, MODASA hereby

1. We have defined our project based on inputs at DESIGN AND MANUFATURING OF

Name Contact No. Sign

Chapter: 2 Literature review……………………………………………….....3

Chapter: 3 Project planning…………………………………………………..4

Chapter: 4 Market survey …………………………………………………....5

Chapter: 5 Detail of project…………………………………………………. .6

Chapter: 6 Design calculations……………………………………………….24

Chapter: 7 Detail drawing…………………………………………………....33

Chapter: 8 Assembly drawing ……………………………………………....35

Figure 2: 4-way lug wrench …………………………………………………………………….14

Figure 3: spark plug wrench ………………………………………………….………………...15

Figure 4: ratcheting box wrench ………………………………………………………………..15

Figure 5: impact wrench, impact driver ……………………………………………….………..16

Figure 6: combination wrench ………………………………………………………………….17

Figure 7: socket wrench ………………………………………………………………………...17

Figure 9: Outline for developing the mechanic…………………………………………………25

Figure 10: The developed mechanism ………………………………………………………….25

Figure 11: Design of gear……………………………………………………….........................28

Figure 12: Design of pinion…………………………………………………….….....................29

Figure 13: Central gear shaft………………………………………………………….…...........30

Figure 14: Pinion shaft …………………………………………………….……………………31

Figure 15: Central shaft key…………………………………………………….….....................31

Figure 16: Pinion shaft key …………………………………………………………………......31

Figure 17: Plates ………………………………………………………………....……………32

Figure 18: Socket ……………………………………………………………..………………..32

Figure 19: Gear ……………………………………………………………….………………..33

Figure 21: Shaft ………………………………………………………………….......................33

Figure 22: Pinion Shaft …………………………………………………………………………34

Figure 23: Key ……………………………………………………………..…….......................34

Figure 24: Bushes and Plates ………………………………………………..….........................34

Figure 25: Sockets ……………………………………………………………….……………..34

Figure 26: Assembly drawing ……………………………………………………......................35

Figure 27: Assembly drawing ………………………………………………………………….35

Figure 28: Working model …………………………………………………………………….36

Table 2: Shafts …………………………………………………………………..……………...21

Table 3: Guide Plate ………………………………………………………...………………….21

Table 4: Parameter ……………………………………………………………….......................28

• The following are the main objective of project

 It develops confidence and creative solution of thinking.