Remote operated fork lift mechanism

working model with sensor controlled

CAPSTONE PROJECT
Submitted in Partial Fulfillment of the
Requirement for Award of the Degree
Of

BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING

By
Neeraj Kumar Reg. No. 11101277
Parshotam Kumar Reg. No. 11109242
Suman Kumar Das Reg. No. 11106400
Tariq Ahmad Ahangar Reg. No. 11114470

Under the Guidance of

Mr. Ankit Bansal
(Assistant Professor)

DEPARTMENT OF MECHANICAL ENGINEERING

LOVELY PROFESSIONAL UNIVERSITY

PHAGWARA, PUNJAB (INDIA) -144402
2014
 Lovely Professional University Jalandhar, Punjab

CERTIFICATE

I hereby certify that the work which is being presented in the Capstone project entitled
Remote Controlled Forklift With Sensor in partial fulfillment of the requirement for the
award of degree of Bachelor of technology and submitted in Department of Mechanical
Engineering, Lovely Professional University, Punjab is an authentic record of my own work
carried out during period of Capstone/Dissertation under the supervision of Mr. Ankit
Bansal, Designation, Department of Mechanical Engineering, Lovely Professional
University, Punjab.

The matter presented in this dissertation has not been submitted by me anywhere for
the award of any other degree or to any other institute. .

Date: Neeraj Kumar

Parshotam Kumar
Suman Kumar Das
Tariq Ahmad Ahangar

This is to certify that the above statement made by the candidate is correct to best of my
knowledge.

Date: Mr. Ankit Bansal

Supervisor

The B-Tech Capstone project examination of Capstone Project, has been held on

Signature of Examiner
 ACKNOWLEDGEMENT

All of us know that the project work is not a single mans job & without the support of
others it is rather impossible to complete the work. We would like to mention certain
individuals who have provided assistance to successfully complete this project.

First & foremost, we express our gratitude to our PROJECT GUIDE, Mr.Ankit Bansal;
without whose able guidance, patience, support and regular encouragement, it would not have
been possible for us to complete this work. We would always remain indebted to him.

We are also thankful to Prof. Jaswinder Singh, Prof. Vijay Shankar, Department of
Mechanical Engineering.

We cant forget the valuable support of our parents also, who have always stood by us,
with their constant and encouragement through out the project work.

In the end, we would not, at the same time, forget to mention the help and moral
support given by our Parents.

Neeraj Kumar,

Parshotam kumar,

Suman Kumar Das,

Tariq Ahmad Ahangar

 CONTENTS

Chapter 1
Introduction 1-5
Chapter 2
Review Of Literature 6-8
Chapter 3
Scope Of Study 9
Work Plan With Timeline 10
Chapter 4
Research And Experimental Work Done 11-22
Result Obtained 23-24
Conclusion 24
Chapter 5
References & Bibliography 25-26
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CHAPTER-01

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 either powered by gasoline, propane, or electricity. Electric forklifts rely 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.

Forklifts are most often used in warehouses, but some are meant to be used outdoors. The
vast majority of rough terrain forklifts operate on gasoline, but some use diesel or natural gas.
Rough terrain forklifts have the highest lifting capacity of all forklifts and heavy duty tyres
(like those found on trucks), making it possible to drive them on uneven surfaces outdoors.

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. Forklift operators also
need to be able to handle forklift's rear wheel steering. Driving a forklift is similar to driving a
car in reverse, meaning that the driver must constantly steer to keep it moving in a straight line.
The driver must be aware of the forklift's ever-changing center of gravity and avoid making any
quick sharp turns or going too fast. It is advisable that anyone who operates a forklift be fully
trained and licensed.

Forklifts have revolutionized warehouse work. They made it possible for one person to
move thousands of pounds at once. Well-maintained and safely operated forklifts make lifting
and transporting cargo infinitely easier. This is the general description of a normal forklift
truck. To enhances the technology further, this prototype module is constructed with remote
technology, there by the operator can walk along with the forklift for better visibility & the
container can be placed accurately (precision position). This increases the safety of the
operator.
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The mechanical structure of this prototype module is constructed with wooden base, Al
channels etc. this structure looks like a horizontal conveying roller & the vertical moving
mechanism that contains metal forks is assembled over the structure at front side. Since it
operates through a remote, it doesnt contain any steering mechanism. The entire vehicle is
designed to drive through two wheels, & two motors are used to drive all the two 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. The DC
Motors are having reduction gear mechanism internally, there by speed is reduced and torque is
increased.

Various fields of technologies are included in this project work, because this system
falls under the subject of Mechatronics. The integration of electronic engineering, mechanical
engineering, electrical engineering, & control technology is forming a crucial part in this design
.The term Mechatronics is used to describe this integrated approach, therefore all above
subjects are described in this project report in following chapters. Most systems that provide
motion and force contain a mixture of Mechanical, Electrical, and Electronic Components. In
fact, today most systems are mixed systems. The design of these mixed systems requires
knowledge from all these fields.

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.

Forklift Classifications

There are seven classes of forklift that describe the fuel option of the forklift and the use.
Each forklift operator must be certified to use on each class of forklift that they will operate.

a. Electric Motor Rider Trucks: - These forklifts can be equipped with either cushion or
pneumatic tires. The cushion tired lift trucks are intended for indoor use on smooth
floors. The pneumatic tired models can be used in dry outdoor applications. These
vehicles are very versatile and are found from the loading dock to the storage facility.
They are generally used in applications where air quality factors need to be considered,
i.e. non polluted areas.
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b. Electric Motor Narrow Aisle Trucks: - This forklift is for companies that opt for very
narrow aisle (passageway) operation. This allows them to maximize the use of storage
space. These vehicles have been developed unique features that are designed to
minimize the space occupied by the truck and to improve speed and efficiency.
c. Electrical Motor Hand or Hand Rider Trucks: - These are hand controlled where the
operator is in from of the truck and controls the lift truck through a steering tiller. All
controls are mounted on the top of the tiller and the tiller is moved side to side to steer
the truck. These vehicles are battery powered with the smaller capacity units using
industrial batteries.
d. Internal Combustion Engine Trucks Cushion Tyres: - These forklifts are used
inside on smooth dry floors for transporting palletized loads to and from loading dock
and the storage area. The cushion tired forklifts are lower to the ground than pneumatic
tired forklift truck. This allows cushion tired forklift trucks more useful in low clearance
applications.
e. International Combustion Engine Trucks Pneumatic Tires: - These trucks are
most commonly seen in warehouse. They can be used either inside or outside and used
in virtually any type of application. Because of the large capacity range of this series of
lift truck, they can be found handling small single pallet loads to loaded 40 foot
containers. These lift trucks can be powered by internal combustion engines and are
available for use with LPG, Gasoline, and Diesel and Compressed Natural Gas fuel
systems.
f. Electric and Internal Combustion Engine Tractors: - These are multipurpose
vehicles & are versatile. They can be used in a variety of applications. They can be
equipped with either internal combustion engines for outdoor use or battery powered
electric motors for indoor use.
g. Rough Terrain Forklift Trucks: - Rough terrain forklifts are fitted with large flotation
type tires for outdoor use on difficult surfaces. They are often used at construction sites
to transport and lift building materials to various job site locations. They are also
common with lumber yards and auto recyclers.

Work Activities Of Fork Lift Truck

Forklift trucks are vehicles designed to move and stack heavy or bulky goods. They are
mainly used in warehouses, stockyards and other storage areas. Forklift trucks are highly
mobile with a very small turning circle which allows them to move easily in confined spaces.
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On the front of the truck are two forks operated by hydraulics. The driver must fit these forks
into the pallets on which goods are stored. The operator then uses the hydraulic forks to lift the
pallet, takes it to where it is needed and sets it down.

Some goods, such as bricks, can be moved by fork-lift trucks without the need for pallets.
They are stacked in bales with spaces for the forks. The operator must work carefully as these
goods are not protected by pallets. Some trucks are fitted with small computer display panels
that direct the operator where to place goods in the warehouse.

Operators may also have to keep records and follow instructions written on a worksheet.
They are also responsible for the basic maintenance of the truck. This includes greasing or
oiling parts and changing or recharging the battery. Forklift truck operators may have to work
in a noisy and dusty environment. Working outdoors in all weather conditions may also be
necessary.

Industrial lift trucks are used for handling materials, parts, products, tools, equipment,
supplies and maintenance items. Forklifts are efficient for material handling because they are
self-propelled, maneuverable and require only one operator to lift, transport, and stack or un-
stack the material. Forklifts may be used for indoor or outdoor use depending on their size, tires
and load capacities. The major factors that lead to injuries involving the use of forklifts include
unsafe driving and material handling practices.

Although the term 'forklift', 'fork lift', or 'fork truck' is instantly recognizable, their full,
official title is a Fork Lift Truck, due to the fork shaped tool at the front that traditionally was
used to lift pallets. But now, like any other piece of equipment, the forklift has evolved and is
available in a wide variety of styles, with varying functions and capacities, depending on where
and how they are to be used.

All lift truck operators must be trained prior to operating a lift truck. Training is provided
by the concern manufacturer and consists of both formal instruction and practical training.
Training is both vehicle- and workplace-specific. The training is a one-time requirement unless
the operator is involved in a lift truck accident or is observed operating the truck in an unsafe
manner.

Industrial lift trucks must be inspected prior to each day of service. A daily inspection
checklist must be completed and any defects should be reported and corrected immediately. A
truck may not be placed into service if any defects are found during the inspection.
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Features Of Fork Lift

Capacity:- Usually forklifts start at around 600 kg load lifting capacity and go up to
52,000 kg, which is a staggering 52 tons. Most forklifts are rated for less than 3 tons.
However, weight is not as straightforward as it may seem. The size of the load will also
impact the capacity. Weight capacity is usually based on a 600 mm (24 inch) load
centre, although this can vary. This means that the distance from the centre of the load
the edges can be no more than 600 mm. If the load is bigger and/or longer, the truck
will not be able to lift as much weight.
Height:-The height that fork lift trucks can lift to varies enormously. Some can lift up
to 11 meters or more (some 36 feet) whereas the basic ones will lift less than 3 meters
(10 feet). Generally, height requirements are fairly static; depending up on the
requirement, lifting height can be adjusted by the manufacturer.
Fork lift safety awareness:-In every wholesaler-distributor operation, stacks, bundles
and rolls of raw material and finished products of various shapes, sizes and weights
must be moved. Excessive and inefficient material handling affects the productivity and
profits. And manual material handling may be dangerous. Efficient material handling
systems and safe operation of material handling equipment such as powered industrial
trucks are the solution.

A powered industrial truck is defined as a mobile, power-driven vehicle used to

carry, push, pull, lift, stack or tier material. Forklifts are one type of powered industrial
truck used by many wholesaler-distributors. Other powered industrial trucks are known
as pallet trucks, rider trucks, fork trucks, or lift trucks. There are many types and sizes
of powered industrial trucks designed for different jobs. Many are named by the
function they perform, such as high lift trucks, counterbalanced trucks, rider trucks and
forklift trucks. Powered industrial trucks refer to as forklifts are used throughout the
wholesale distribution industry to move raw materials and stock and to elevate
personnel.
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CHAPTER-02

REVIEW OF LITERATURE

Kenneth B. Ackerman (1990), Forklifts and Other Mobile Equipment, Practical

Handbook of Warehousing

ABSTRACT
Widespread use of the forklift truck had revolutionized warehousing practices before
the middle of the 20th century, enabling warehouse operators to justify erecting sprawling one-
floor buildings to replace the more compact multi-story structures used in the past. Many kinds
of mobile equipment are used in warehouses today, but most are variants of the common
forklift truck.

Dr.R.N. Mall (2013), Automated Guided Vehicle, ISBN 2091 Journal, MMMEC, Gorakhpur.

ABSTRACT

The material handling function reflects on the efficiency and speed of warehouse
operation, which eventually outcome in stretched out of dense order conclusion period. For
designing an effective and efficient material system, the guidelines normally followed
are:

Designing the system for continues flow of material, i.e. idle time should be zero.
Going in for standard equipment, in which ensures low asset and elasticity in
the use in material handling needs in the future.
Incorporating gravity flow in material flow system
Ensuring that the ratio of the dead weight to the payload of material handling
equipment is minimum.

Material handling is designed for safe transportation. Due to globalization of the

economies of many countries, companies all over the world are making efforts to
further expand their business areas. So the need for container transportation is being
increased, and container terminals should satisfy such needs. For example, container
terminals should provide better services to meet needs, should handle materials more
speedily, and should reduce the cost. Since there are the same needs in other countries as
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well, the 365-day 24-hour operable container terminals should be constructed. To meet the
above-described needs, companies should establish.

A mixture of material handling systems is in the use, exact from that entirely
physical to the ones that are semi-automatic but manually controlled. It is the giving use as per
in factors such as:

Volume to be handling.
High speed in behaviour
Efficiency.
Product kind such as, shape ,size and weight
Character of the item for consumption ( perishable, crushable, hazardous)

Monorail and other guided vehicles, certain types of conveyor System and certain
type of crane operation .we assume that the vehicle operation at stable velocity during the
operation and pay no attention to special effects of acceleration, deceleration and
additional speed differences that depend on the vehicle loaded or empty or other manner .A
very typical delivery system in the operation of a vehicle, based transport system consists
of:

i. Loading at the pickup station.

ii. Travel time to the drop-off station.
iii. Unloading at the drop-off station.
iv. Vacant moving time of the vehicle to the deliveries.

The load cycle time per delivery per vehicle is given by

= + + +

Where

i. Tc =delivery cycle time (min/del).

ii. Tl= time to load at load station (min.).
iii. LD= distance the velocity travel between load and unload station
iv. v=carrier velocity (m/min),
v. TV= time up to unload at unload station (min).
vi. Le =distance the vehicle travel empty until the start of the next delivery
cycle (m). The delivery cycle time will used to find out all the
parameter of attention in the vehicle-based t.
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FACTORS

25 % Employee reduced
55 % Factory space
87 % Reduce production time to material handling.

S.No FORKLIFT USES (%) YEAR UTILIZATION (%)

1 20 2009 63.0
2 40 2010 69.8
3 60 2011 81.9
4 80 2012 83.4
5 100 2013 87.9

Here is a graphical representation of usage increment as per research article data by Dr.
R.N. Mall, MMMEC, Gorakhpur, India.

UTILIZATION INCREMENT

100
80
60
40
20
0

2009
2010
2011
2012
2013

UTILIZATION INCREMENT
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CHAPTER-03

SCOPE OF THE PROJECT

The forklift prototype is a four-wheeled that has the ability to follow the direction
guided by the operator. There are four wheels including two driving wheels controlled by two
motors and two free wheels in front that is able to rotate 360. With four wheels, both driving
wheels are always in contact with the surface.

This project consists of four main stages, which are theoretical design, mechanical
fabrication, electronic hardware design.

Market Survey

A market survey is an important requirement for initiating any successful business. The
objective of a market survey is to collect information on various aspects of the business. This
survey is a tool through which we can minimize risk. After the market survey, the results must
be analyzed in order to finalize a business plan.

We are implementing manually guided vehicle, which replaces the normal transporting
methods. So that we wants to consider all the sections related to this works such as problems
arising while installing. So we conducted a market survey by personnel interview techniques
was used with the measure emphasis on personal interview method. Interviews were conducted
through the structure questionnaire, Also we go through people who work in large industries
such as production plant, supply station etc.
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Completed Work Plan With Timelines

S.No Duration Work Target Work Done Learning Outcome

Analyzed Different Research
Literature Survey Papers And Found To Do
1 Janaury14 & Completed Some Modification In The
Formulate The Concerned Topic Which Is
Problem Based On Remote Operated
Forklift.
1:-Need Of The Product
2:-Define The Product
3:- Requirements Of The
Market Survey Product. Requirements
2 Feburuary14 & Completed Include The Output Capacity
Design Consideration Of The Machine, Service Life,
Cost And Reliability.
4:-Availability Of The
Material
5:-Selection Of The
Mechanism.
1:-Design Of Individual
Components. It Consists Of
The Following Steps:
(a) Select appropriate
Fabrication Material.
3 March14 & Completed (b) Determine the
Assembly physical parameters
Of The Component.
2:-Assembly Of All The
Designed Components.
Testing 1:- Testing Of All The
4 April14 & Completed Components.
Calculation 2:-Calculation Of Different
Components .
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CHAPTER-04

RESEARCH AND EXPERIMENTAL WORK DONE

Different Components Used

Different components used in this project are as given below:-

1. Base (Chasis)
2. Steering System
3. Slider
4. Bevel Gears
5. Shaft
6. Nylon Rope
7. Pulleys
8. DC Motor
9. Six Pins Wired Remote Control

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 of 3kg.

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.

2. STEERING SYSTEM

The steering system used in the model is of differential type. A differential wheeled
vehicle is a vehicle whose movement is based on two separately driven wheels placed on either
side of the body. It can thus change its direction by varying the relative rate of rotation of its
wheels and hence does not require an additional steering motion. It allows the turning centre to
be on the vehicle body thus the ability to rotate on the point.

If both wheels rotate at the same speed and in the same direction, the forklift will move
in a straight line.
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Small Radius Turning

3. SLIDER

Its a rectangular plate which is held between two vertical channels of Aluminium 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.
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4. Bevel Gears

The bevel gears are used for transmitting power at a constant velocity ratio between two
shafts whose axis intersects at a certain angle. The pitch surfaces for the bevel gear are
frustums of cones. The elements of the cones intersect at the point of intersection of the axis of
rotation. Since the radii of both the gears proportional to their distances from the apex,
therefore the cones may role together without sliding. The elements of both cones dont
intersect at the point of shaft intersection. Consequently, there may be pure rolling at only one
point of contact and there must be tangential sliding at all other points of contact. Therefore,
these cones cannot be used as pitch surfaces because it is possible to have positive driving in
sliding in the same direction at the same time. We, thus conclude that the elements of bevel
gear pitch cone and shaft axis must intersect at the same point.

5. 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 to bending. 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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6. NYLON ROPE

The rope is used to transmit power from one point to another by means of pulleys which
rotate at the same speed or at different speeds. The amount of power transmitted depends upon
the following factors:

a. The velocity of the rope.

b. The tension under which the rope is placed on the pulleys.
c. The condition under which the rope is used.

7. PULLEYS

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. In our model we use plastic pulleys.

8. DC 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 Flemings Left Hand Rule.
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9. SIX PIN WIRED REMOTE CONTROL

The forklift is equipped with 6 manual keys. By activating these keys manually, all the
movements can be created in the forklift. All these 6 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.

COMPONENTS OF WIRED REMOTE CONTROL

a. Diode

b. Resistor

c. 6 Switches

d. Filter Condensor

PHYSICAL PARAMETERS OF ALL THE COMPONENTS USED

Dimension of Base
Length of Base: 44cm
Height of Base: 35cm
Thickness of Base: 3cm
Height of Bed From Flat Surface: 10cm
Dimension Of Sliding Mechanism
Height of Rails/Channels: 60cm
Width of Rails: 12cm
Thickness of slider: 1.3cm
Size of slider: 13*10cm
Motors used
Type: DC Motor
Speed: 30 rpm
Capacity: 12V & 1Amp
Number Of Motor Used: 3
Gears specification
Type of Gears used: Bevel gear
No. of Teeth of Driver Gear: 11
No. of Teeth of Driven Gear: 42
Diameter of Driver gear: 24mm
Diameter of Driven gear:82mm
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CALCULATIONS

Gear Ratio(G)
Its the ratio of number of teeth on Gear to the number of teeth on Pinion. Its
denoted by capital letter G.
Mathematically,

Gear Ratio (G) =

G=

G=

G=3.818

Therefore G= 4 (appr)

Velocity Ratio (V.R)

Its the ratio of speed of the follower (gear) to the speed of the driver (pinion).Its
denoted by V.R.
Mathematically,

( )
Velocity Ratio (V.R) =
( )

V.R=

We know that:

Tg= 42

Tp= 11

Np= 30 rpm

Ng=?
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For velocity Ratio,

Ng= Np

Ng= 30

Ng = 7.857 rpm

Therefore, Ng = 8 rpm (appr)

V.R =

V.R=

V.R = 0.2667

Pitch Angle And Pitch Radius:

Pitch Angle: The angle that the pitch line makes with the axis of the gear is

called the pitch angle. Its denoted by . The pitch angle is also called centre
angle.

Pitch Radius: Its the length of the back cone element. Its also called back

cone radius. Its denoted by . r

Measured Data

Shaft Angle =90

Speed of Pinion, Np = 30 rpm

Speed of Gear, Ng = 8 rpm

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Figure 6.1 for Pitch Angle And Pitch Radius

Pitch Angle of Gear,

Tan g =

Tan g=

g = 75.06

Or

g = 75 (appr)
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Pitch angle of pinion:

Tan p =

Tan p=

p = 14.9315

Motor Calculation:

Voltage E = 12V

Ampere I = 1Amp

Mechanical power developed by motor:

P= VI

P= 121

P= 12 watt

Torque = 9.55

T=9.55

T = 3.82 Nm

Or, we also know that

P =T

Or T = =

T =

T = 3.82 Nm
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CIRCUIT DIAGRAM

The electrical circuit diagram of our project is shown in below figure.

Figure 6.2 Circuit Diagram

REMOTE OPERATION

S. No Switch Operation Mode

1 S1 + S3 Forward Direction

2 S2 + S4 Reverse Direction

3 Only S1 Right Turn

4 Only S2 Left Turn

5 Only S5 Upward Direction

6 Only S6 Downward Direction

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ACTUAL IMAGES OF THE PROJECT

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ADVANTAGES AND DISADVANTAGES OF FORKLIFT

ADVANTAGES OF FORKLIFT

Suitable for indoor use.

Longer life.
Minimum noise level.
Eco-friendly operation
It can be used in hazardous areas.
Huge advantage of forklift is that they have no fuel cost.
The best electric forklift is that they have zero emission which causes safe and healthy
environment. That is why they can be called the Green Forklift.
The operation cost is low.
The life of electric forklift is greater than other types.
Maintain better control of material management
Reduce product damages
Reduce manpower
Increase productivity
Suitable to transfer frames

DISADVANTAGES OF FORKLIFT

The speed is low.

The capability of lifting weight is lower than other forklifts.
You cant handle it until you are fully trained.
They are usable only indoor.
The main disadvantage is the area should be properly dry and should have controlled
temperature, otherwise you face accidents.
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RESULTS

SPECIFICATION

Base
Length of Base: 44cm
Height of Base: 35cm
Thickness of Base: 3cm
Height of Bed From Flat Surface: 10cm
Sliding Mechanism
Height of Rails/Channels: 60cm
Width of Rails: 12cm
Thickness of slider: 1.3cm
Size of slider: 13*10cm
Motors used
Speed: 30 rpm
Capacity: 12V & 1Amp
Number Of Motor Used: 3
Gears specification
Type of Gears used: Bevel gear
No. of Teeth of Driver Gear: 11
No. of Teeth of Driven Gear: 42
Diameter of Driver gear: 24mm
Diameter of Driven gear:82mm

RESULTS OBTAINED

Speed of Gear
Ng = 8 rpm
Gear Ratio
G=4
Velocity Ratio
V.R = 0.2667

Pitch angle of Gear

g= 75
Pitch angle of Pinion
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p= 15
Torque
T = 3.82 Nm
Power
P = 12 watt

CONCLUSION

The project work Remote operated forklift is aimed to control through wired
communication network designed with RF modules. The main advantage of using this
technology is to increase the safety of operator by operating the forklift from certain distance.
This increases the efficiency of the productivity, because human errors due to the poor
visibility can be minimized. The system is designed and developed successfully, for the
demonstration purpose prototype module (mini module) is constructed & results are found to
be satisfactorily.

After going through these collected data and statistics from various journals as well as research
papers; we came to conclusion that remote controlled fork lift is the only way to stop such
industrial issues like labour cost, hazardous material handling.

Most of all human safety is a major concerns by using a remote controlled forklift. We can use
our human brain but the hands and legs of a robot, and thereby nullifying the chances of
accident.

Our project is just a prototype, in which we have not used any electronic micro-controller in its
IC. Ours has a simple electrical heart and a simple mechanical body. As this is the simplest one,
we have got wired remote for manual operating. It can be modified into any high class
application. Considering the project time and all the necessary steps, we concluded this project
is the right one.

This robot can be used as an aid for who are bound to use wheel-chair. Since just a simple
modification in its mechanical arm and movement way, we can convert into any robot that can
perform a special type of work.
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CHAPTER-05

REFERENCES

Books & Journals

R S Khurmi, J.K Gupta (2005), A text book of Machine Design.
S S Rattan (2009), Theory Of Machines, Professor Of Mechanical Engineering,
National Institute Of Technology, Kurukshetra.
V B Bhandari (2010), Design Of Machine Elements, Retired Professor And Head
Department Of Mechanical Engineering, Vishwakarma Institute Of Technology, Pune.
J B Gupta (2011), Basic Electrical & Electronics Engineering.
B L Thareja, A K Thareja Revised By S G Tarnekar (2005), Electrical Technology,
Former Professor & Head, Electrical Engineering Department, Visvesaraya National
Institute Of Technology, Nagpur.
From Vol. IV Number 1 of Warehousing Forum 1988, The Ackerman Co.
Significant contributions to the AGVS material came from Tom Ewers of Kalmar AC
Handling Systems, Bob MacEwan of Clark Lift of Columbus, and Russ Gilmore of
Autocon in Dayton, Ohio. Portions appeared in Vol. 20, No. 6, Warehousing and
Distribution Productivity Report, Marketing Publications, Inc., Silver Spring, MD.
Conte M, Pasquali M (2009) Impact of innovative ILHYPOS super capacitors on a
fuel cell vehicle, international electric vehicle symposium EVS-24. Stavanger, Norway
Conte M (2010) Super capacitors technical requirements for new applications. Fuel
Cells 10:806818.
Conte M, Pede G, Rossi E, Vellucci F (2010) Super capacitors research and
applications at ENEA, ESSCAP2010. Bordeaux, France
Chiodo E, Lauria D, Pagano M, Pede G, Vellucci F (2013) Experimental
performances and life cycle estimation of hybrid electric storage systems, IEEE
International Conference on Clean Electrical Power (ICCEP 2013)
Kuperman Alon, Aharon Ilan (2011) Battery-ultra capacitor hybrids for pulsed
current loads: A review. Renew Sustain Energy Rev 15:981992
Burke A (2007) R&D considerations for the performance and application of
electrochemical capacitors. Electro chim Acta 53:10831091
Cericola D, Kotz R (2012) Hybridization of rechargeable batteries and
electrochemical capacitors: principles and limits. Electro chim Acta 72:117
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BIBLIOGRAPHY
http://link.springer.com/search/page/2?query=electric+forklift
http://en.wikipedia.org/wiki/Forklift_truck
http://www.nptel.co.in
http://www.mitboston.co.in