HUMAN POWERED FORKLIFT

HUMAN

POWERED

FORKLIFT

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CERTIFICATE

This is certified that the Project entitled, Human Powered Forklift has been carried out
under my supervision in partial fulfillment of the requirement of B. Tech. in Mechanical
Engineering.

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ACKNOWLEDGEMENT
We deem it a privilege to have been a student of Mechanical Engineering stream in. We take
this opportunity to express my gratitude to all those who motivated, encouraged and help in
the project work. I’m grateful to my supervisor and co supervisor for their kind support,
guidance and encouragement throughout the project work also for introducing to us this topic,
which has been very interesting and has given us great insight to the future work on this
area .Their continuous support gave us the strength for pursuing our dream. Special thanks to
our friends and other members of the department for being so supportive and helpful in every
possible way.

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ABSTRACT

Mechanical Forklift is a new and advance technique use in mechanical industry line. Forklift
handle more material and transfer one place to another place. Because of forklift it is possible
that one operator is sufficient for material handling. When technology is improved, advance
forklift was developed, they operate with the help of remotes, and it requires an electricity as
cost of remote operated forklift is high so that a human powered forklift is introduced.

A population of India is very large so that the main of any industrial company to fulfill a
customer requirement due to that extra workload in mechanical industry line. This work load
causes increasing stresses on the workers. Workers are prone to unhealthy condition. To
minimize a stresses factor on a worker some material handling machines are developed.

Human Powered forklift consist of frame which is made of steel square bars which are welded
together to form structure. The wheels are provided for turning purpose.

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TABLE OF CONTENT

Chapter No. Content Page No.

Certificate ii

Acknowledgement iii

Abstract iv

Table of Contents v

List of Figure 6

1 INTRODUCTION 7

1.1 Forklift Classification 8

1.2 Aim of Forklift 10

2 LITRATURE REVIEW 11

3 WORKING PRINCIPLE OF FORKLIFT 12

4 COMPONENTS & MATERIAL 13

4.1 Types of Fork 15

5 VIEW OF FORKLIFT 16

6 DETAILS OF MOTOR & FORK 17

7 MATERIAL & EQUIPMENT REQUIRED 18

7.1 Advantages & Limitations 19

8 CONCLUSION 20

8.1 Pictures while Assembling 21

9 FUTURE SCOPE AND OUTCOME 23

REFFERENCES 24

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LIST OF FIGURES

Figure No. Figure Name Page No.

1 Forklift 7
2 Counterbalance Forklift 8
3 Pump truck 9
4 Teletrucks 9
5 Forkarms 11
6 Human Powered Forklift 12
7 Components & Material 13,14
8 Pin mount & Hook mount Fork 15
9 Views of Project 16
10 Images while assembling 21,22

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Chapter - 1
INTRODUCTION

In general, the forklift can be defined as a tool capable of lifting load of tons. A forklift is a vehicle similar
to a small truck that has two metal forks on the front or side used to lift the load. The forklift operator drives
the forklift front until the forks push under the cargo, and can lift the cargo to the required height in the air
by using the forks. The forks are usually made out of steel and can lift up to a few tons. Forklifts are either
powered by petrol or electricity. Electric forklifts relay on batteries to operate. Petrol forklifts are heavy
duty and faster than electric forklifts, but they are difficult to maintain and operate so fuel cost is higher.
Electric forklifts are best for warehouse use because they do not produce noxious fumes and noises like gas
powered machines do. Some forklifts are meant to be used outdoors too. The majority of rough terrain
forklifts operate on petrol, and some use diesel or natural gas. Rough terrain forklifts have the highest
lifting and loading capacity and heavy-duty tires, making it possible to drive them on all terrain. Forklifts
plays revolutionary role in warehouse work of carry loads. They made it possible for single person to move
thousands of kilograms at once. Well-maintained and safely operated forklifts make lifting and transporting
cargo infinitely easier.

Fig 1: Forklift

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1.1) 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.

1. Counterbalance: – Counterbalance forklifts are the most common trucks used in virtually all material
handling capacities. Counterbalance forklifts are straight forward appliance that features dual forks for
heavy loads and bulky items.

Fig 2: Counterbalance

2. Three-Wheel Counterbalance:– These forklifts feature three wheels as opposed to four in their
counterbalance forerunners. Three-wheel counterbalance forklifts are ideal for narrow aisles as they have
enhanced maneuverability for tight spaces.

3. Reach Trucks – Reach trucks are known for what they are named after, their extended lift height. Reach
trucks are optimal in any warehousing situation with high rise.

4. Pump Trucks – Pump trucks are considered a bit of a throwback. Pump trucks are primarily used as a
pallet jack but do not use any electric power to lift any materials. Instead, pump trucks rely on good old-

fashioned manual labour as the operator “pumps” the jack to lift the skids with their own
force.

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Fig 3: Pump Truck

5. Powered Pallet Trucks – Conversely, the powered pallet truck is a modernized innovation of a pump
truck. The powered pallet truck does all the heavy lifting for you! Mirroring functionality of a pump truck,
powered pallet trucks are ideal for skids and small packages that need to be stored or transported.

6. Side loaders – Side loaders are primed to operate in narrow aisles as well.  Side-lines feature forks which
are mounted to the side of the truck and are designed to pick up wide or long loads that would cumbersome to
the typical forklift. Just like many other species of forklift, these to come in various forms. First is the
Enclosed Cab that is frequently used outdoors and the Stand-Up which is geared to handle indoor
assignments.

7. Teletrucks – Short for telescopic hander forklift, these devices are another option for users that are tasked
with high lifting or facilitation of mezzanine storage. These devices are often mistaken for cranes and are able
to reach heights and angles that standard lift trucks cannot.

Fig 4: Teletrucks

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1.2) AIM OF FORKLIFT

 To help peon or any other workers to transport the good in less time, in less effort, easily and
comfortably.

 To modify and improve mechanism of forklifts.

 To make effective loading/ unloading of goods.

 To make activities/ procedure environment friendly.

 To reduce cost of operation by substituting gasoline engine.

 Increase safety at workstation.

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Chapter 2
Literature Review
 Literature Survey:-

3-D Research On Fork Arms Of Forklift Trucks:-

This article is developed by “Yanko SLAVCHEV”, Proceedings of the international Conference on

Manufacturing System.

This article presents a research, conducted by 3-D computer models and the finite element method (FEM), on
the stressed state of fork arms of forklifts. Several modes of attachment to the carrying plate have been taken
into consideration. Special interest has been paid to the stressed state of the folded region and the console
welds for arms attachment. A multi-objective optimization, specifically a goal driven optimization (GDO), is
performed to estimate the length of the fork arm when it is loaded by a payload, placed on a wooden pallet.

Fig 5: Forkarm

Figure 7 Design of Fork

Where 1-Forkarm, 2-Carrying console, 3-limiting console, 4-carrying plate, B and S- width
&thickness, (a) DIN mode of attachment, (b)- ISO mode of attachment, S1- Folded region
thickness, r and R- Folded region radii, L-length of working area, h d f- carrying plate
parameters.

Chapter 3
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WORKING PRINCIPLE OF FORKLIFT

 Forklift is a small industrial vehicle, having a power operated forked platform attached at the front
that can be raised and lowered for insertion under a cargo to lift or move it. Forklifts serve the needs
of various industries including warehouses and other large storage facilities.

 Forklifts are powered by electric battery. Some Forklifts allow the operators to sit while driving and
operating the machine while others require the operator to stand. It is being extensively used
throughout the industry for transporting materials and goods.

 Lifting Mechanism: Motor and pulley are attached to the two main vertical structures called the
"masts." However, the actual forks that carry the load are attached to the main body of the forklift.

 Controls: We used push button and 2 way switch to lift and release fork.

Fig 6: Human Powered Forklift

Chapter 4

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COMPONENTS & MATERIAL

1. Supporting frame Material: M.S. plate

2. Electric motor Material: standard

Capacity: 12 v DC, 350 RPM

3. Wheel Material: Polyurethane

Size: 10”

4. Battery

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5. Caster

6. Nut & Bolts

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4.1) Types of Forks: -

Forks are the main part of forklift, which used for lift the load in the forklift. As per the ITA (International
Technology Association) standard there are mainly two types of fork joints are in the use. We has used pin
mount for our light weight.

1) Pin mounts (Low Load)

2) Hook Mounts (High Load)

Chapter 5
VIEW OF THE FORKLIFT

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Front view Top View

Left hand side View Right hand side View

Chapter 6
DETAILS OF MOTOR AND FORK

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1) Selection of Motor
 Required torque of motor (M_t) = 10613.42 Nmm

 Required speed of motor (N) = 350 rpm

 Type of supply to motor = 12 Volt D.C.

Torque required to raise maximum load in Kg-cm = (M_tRAISE )/(9.81 ×10)

= 10613.42/(9.81 ×10)

= 108.1 kg-cm

Required speed of motor shaft in rpm = 350 rpm

We have to search market carefully then we find no motor available with this specification so we
choose a motor with 350 rpm 100 Kg-cm torque motor.

Parameter Motor Specifications

Type of motor D.C. Car Window Motor
Speed of motor 350 rpm
Output torque of motor 100 Kg-cm
Input voltage and current 12 V 0.7A

2) Design of Fork
 Outer face height (D) = 50.8 mm

 Outer face width (B) = 50.8 mm

 Inner ace height (d) = 44.8 mm

 Inner face width (b) = 44.8 mm

 Length of fork (L) = 600 mm

Chapter 7
MATERIALS AND EQUIPMENTS REQUIRED

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 Equipment Required:
1. Hacksaw Cutter or Machine
2. Welding Machine
3. Hand Drilling Machine
4. Colour sprayer

 Tools Required:
1. Cutting tools (for above stated machines)
2. Hacksaw
3. Hammers
4. Measure tape
5. Spanner set
6. Screwdriver

 Materials Required:
1. M.S. Plate (7 mm thick)
2. M.S. Hollow round bars
3. Arc welding electrodes
4. Spraying colour
5. Coolants and oil
6. Fasteners
7. Safety wears

7.1) ADVANTAGE

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1. The loading and unloading process is easily done by this machine

2. This machine is faster as compared to existing machine

3. This machine is safe for worker during the material handling.

4. Easy to maintenance.

5. Cost effective.

6. Easily Attachable & Detachable

7. Industrial Goods Transport

8. Warehouse Internal Transport

LIMITATION

1. Applicable for small scale industry

2. High lifting height is not obtained

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Chapter - 8

CONCLUSION

From the on top of knowledge it's conjointly ascertained that using forklift, problems of
workers and transporters will be solved. From the practicality we’ve found reliable way to
satisfy needs of workers. From the on top of literature survey, it's evident that the design and
model of Human Powered forklift is a unique concept. It can Withstand Unit amount of load
without failure. Using High torque motor can increase Effectiveness and load Capacity of
Forklift. Goods from small warehouses or college campus can be easily transported with
minimum time. Effectiveness compared to pure human power is better. Overall, It`s reliable and
Effective concept for Forklift Technology.

The forklift is used to transfer material from one place to another place. These are used in
commercial areas like Industrial Workshops, warehouses, Car servicing station, Institutes,
Material handling and construction applications.

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Chapter - 9

FUTURE SCOPE AND OUTCOME

 Robotic arms can be added to the fork to simplify work of loading and unloading objects
on the fork.

 Forklift can be converted to the complete automated machine, by which we can control
the forklift from the cabin as like AGV (Automated Guided Vehicle).

 Loading capacity can be improved of forklift by enlarge the size of fork and with the help
of heavy torque motor.

 Hydraulic system can be attached behalf of mechanical system.

 Chain drive or gear drive system can be used at the place of Rope drive mechanism.

 Total height of lifting can be maximized.

 Cost of Product can be reduced by Batch production.

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REFERENCES

1) R S Khurmi, J.K Gupta (2005), A text book of Machine Design. 5) S S Rattan (2009),
Theory of Machines, Professor of Mechanical Engineering, National Institute of
Technology, Kurukshetra.

2) R.P.Kumar Rompicharta – PG Student Dr. K. Rambabu – Associate Professor,” Design

and analysis of drive shaft with composite materials” Affiliated to Andhra Pradesh
University, Research Expo International Multidisciplinary Research Journal Volume-II,
Issue- IIJune- 2012

3) ISO Standard 2328-2007, Fork-lift trucks- Hookon type Fork Arms and fork arm
carriage – Mounting dimension ISO, second edition, 2007.

4) “Forklift Stability and Other Technical Safety issues” Accident research centre Monash
University Victoria 3800 Australia, an initiative funded by worksafe, Victoria, April 2003

5) Rangaswamy,T: Vijayrangan, S. 2005 “optimal sizing and stacking sequence of

composite drive shaft”.

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