“Working Model of Manual Hand Stacker”

SUBMITTED TO

Gujarat Technological University-Ahmadabad

IN PARTIAL FULFILLMENT OF THE REQUIRMENTS FOR THE AWARD OF

DIPLOMA IN
MECHANICAL ENGINEERING

SUBMITED BY

Ruturajsinh Jadeja 186620319018

Deep Bhalodi 186620319003
Jaimeen Makawana 186620319028
Ronak Dhrangadhariya 186620319012

GUIDED BY

Prof. Dharmesh Tanti

Mechanical Engineering Department,

Darshan Institute of Engineering& Technology
For Diploma Studies
RAJKOT

2020-2021

DEPARTMENT OF MECHANICAL ENGINEERING

DARSHAN INSTITUTE OF ENGG & TECHNOLOGYFOR DIPLOMA STUDIES
RAJKOT-MORBI HIGHWAY, RAJKOT, GUJARAT

Mechanical Engineering Department

DIETDS Rajkot Page 1
 CERTIFIE

This is to certify that Ruturajsinh S. Jadeja, Deep B. Bhalodi, Jaimeen H.

Makawana and Ronak R. Dhrangadhariya student of Darshan Institute of
Engineering and Technology in Diploma Studies having Enrolment no:
186620319018,186620319003,186620319028 and 186620319012 has
completed Semester-V Project Report having the title “Working Model of
Manual Hand Stacker”. In a group consisting of a single person under the
guidance of the faculty guide Prof. Dharmesh D. Tanti.

Institute Guide Head of Department

2020-2021

DEPARTMENT OF MECHANICAL ENGINEERING

 EXAMINER’S CERTIFICATE OF APPROVAL

This is to certify that draft report entitled “Working Model of Manual Hand Stacker”

Submitted by,

Ruturajsinh Jadeja 186620319018

Deep Bhalodi 186620319003
Jaimeen Makawana 186620319028
Ronak Dhrangadhariya 186620319012

In partial fulfillment for the award of the diploma in “Mechanical Engineering” of the
Gujarat Technological University-Ahmadabad is here by approved.

Examiners:

2020-2021

DEPARTMENT OF MECHANICAL ENGINEERING

DARSHAN INSTITUTE OF ENGG & TECHNOLOGYFOR DIPLOMA STUDIES
RAJKOT-MORBI HIGHWAY, RAJKOT, GUJARAT.
 ACKNOWLEDGEMENT

I express my cavernous sense of obligation and gratitude to my guide Prof. Dharmesh Tanti
for his genuine guidance and constant encouragement throughout this project work. I am
highly obliged as my honourable guide have devoted his valuable time and shared his
expertise knowledge.

I would like to thank Mechanical Engineering Department- Darshan Institute of Engg. &
Technology for Diploma Studies- Rajkot for their valuable support.

I extend my sincere thanks to H.O.D.Prof. M.V. Vekariya, Department of Mechanical

Engineering and Principal Prof. M. V. Sanghani, Darshan Institute of Engg. & Technology
for Diploma Studies, Rajkot for providing me such an opportunity to do my project work.

I also wish to express my heartfelt appreciation to my friends, colleagues and many who have
rendered their support for the successful completion of the project, both explicitly and
implicitly.

Ruturajsinh Jadeja 186620319018

Deep Bhalodi 186620319003
Jaimeen Makawana 186620319028
Ronak Dhrangadhariya 186620319012

5thMechanical

Place: D.I.E.T.D.S, Rajkot

 ABSTRACT

In today's competitive market, quality products at low cost and timely delivery are highly
required. To minimize the setup time Manual Hand Stacker is developed. In this project
weight lifting is easy way to weight lifting. The machine is used to easily weight lift. It makes
it easier for people to work. They can lift the weight by rotating the pulley and bring it up and
down by rotating the other side. It does not require electricity. It does not require electricity
so there is no danger of getting electricity. It also works where there is no electricity. Your
work stops when the power goes off when you take a light weight lift. Because of this you
have become a Manual Hand Stacker that runs without electricity. It is used in most
industries.
 INDEX

SR. NO. TITLE PAGE NO.

1 INTRODUCTION 7 to 15
2 LITERATURE REVIEW 16 to 20

3 ASSEMBLY & DETAIL DRAWING 21 to 31

4 FUTURE WORK 32 to 33

5 REFERENCE 34 to 35
CHAPTER-1 INTRODUCTION
1.1 Introduction

In every manufacturing industry need of automation is must due to fast progression in

consumption of manufactured product. Demand of quality products in short time duration is
must in current scenario. Improved quality in products can be achieved by the usage of
advanced technology as well as automatic machineries. We need systems made with the latest
technology to make our work easier. Generally, Electric Hand Stacker are used for
manufacturing product or anything that can be used in life to put specific dimensional
products with a large volume or small volume. Electric Hand Stacker are those machines
which are not available off the shelf, Therefore those have to be designed and made as per
customer`s specific requirement. They are also called as forklift machine. In this project we
only focused on the study of which simplifies what human beings do as well as development
of A machine that can easily lift anything.

Highly automated Production simplification machine realization has been an important mean
for industry to meet the competition from low-cost countries, primarily due to relative high
wage cost observed in e.g. the US and in Europe (Kilbo 2001; Teknisk framsyn 2000).
Throughout the 20th century, extensive efforts to develop easily production processes where
used by manufacturing companies to radically increase efficiency and sustain a high quality
of production. Increased automation was not only concerned with actual manufacturing
processes, but also focused on supporting tasks (e.g. material handling, transport and storage)
(Reveliotis 1999). However, even if there were ambitions during the 1980’s even to create
socalled “lights- out factories” with full automation in each production unit (Mital 1997),
most automated systems within manufacturing are still semi-automatic with manufacturing
systems consisting of combinations of automated and manual tasks. This is especially
apparent within assembly operations, which have generally been more difficult to automate at
a justifiable cost (Boothroyd 2005). In addition, product customization demands and
increased product complexity have resulted in increasingly complex manufacturing systems
as well as increased levels and extent of automation (Satchell 1998). However, neither
automation to fulfill efficiency requirements, nor automation to achieve flexibility does
necessarily lead to expected results (Youtie et al. 2004). In fact, excessive levels of
automation (LoA) may result in poor system performance (Endsley 1997; Endsley and Kiris
1995; Parasuraman et al. 2000). Further, complex manufacturing systems are generally
vulnerable to disturbances, which might lead to possible overall equipment efficiency (OEE)
degradation (Ylipaa 2000). In parallel, degraded operator performance may be caused by e.g.
lack of knowledge, gradual loss of special working skills, degradation of situation awareness
(Endsley 1997; Endsley and Kiris 1995; Parasuraman et al. 2000), or unexpected increase in
cognitive workload (Connors 1998)
1.2 Definition

Electric Hand lift is a forklift truck powered by an electric motor instead of an internal
combustion (IC) engine using either rechargeable industrial batteries or external ways of
conveying power (wire, rail, etc.).

1.3 Problem Specifications

Forklifts are rated for loads at a specified maximum weight and a specified forward center of
gravity. This information is located on a nameplate provided by the manufacturer, and loads
must not exceed these specifications. In many jurisdictions, it is illegal to alter or remove the
nameplate without the permission of the forklift manufacturer.

1.4 Objective

 Review the information below on how to use hand pallet trucks safely.
 Lead a discussion to help workers apply the information to your workplace.
 Briefly review the operating instructions for hand pallet trucks with the group. Ask an
experienced worker to demonstrate working with a hand pallet truck.
 Discuss hand pallet truck incident and injury prevention strategies. Use past incidents
to stress the importance of safe operation.
 Review the important points.
 Have workers take the True/False quiz to check their learning

1.5 Classification

 Electric Hand Lift

 Personnel lifts
 Order pickers
 Hydraulic Lift
 Pneumatic Tire Lift
 Container Handlers
 Narrow Aisle Forklift
1.5.1 Electric Hand Lift

Fig: 1.5.1 Electric Hand Lift

Hyundai Electric Forklifts are an ideal choice for warehouse loading and unloading
operations. Their compact design makes them suitable for working even in narrow aisles.
Moreover, their best-in-class specifications and state-of-the-art features enable smooth and
quick operations. With a load capacity ranging from 1500 kg to 4990 kg, you can choose
from a variety of options depending upon needs.

1.5.2 Personnel Lift

Fig: 1.5.2 Personnel Lift.

An elevator (North American English) or lift (Commonwealth English) is a type of vertical
Cable Transportation machine that moves people or freight between floors, levels, or decks of
a building, vessel, or other structure. Elevators are typically powered by electric motors that
drive traction cables and counterweight systems such as a hoist, although some pump
hydraulic fluid to raise a cylindrical piston like a jack.
1.5.3 Order Pickers

Fig: 1.5.3 Order Pickers.

An order picker or order picker is defined as a person or a piece of equipment used to pick
and deliver material needed for filling orders from storage.
The machine known as an order picker is an electric lift truck specifically designed for filling
individual customer orders which require piece-part or case picking, rather than full pallets or
unit loads. Order pickers are used at elevations higher than the second level of racking in a
warehouse or distribution center. They can reach heights up to 390″ Order pickers are
typically powered by 24- or 36-volt industrial batteries. Order pickers will be used in
applications where pallet trucks, rolling ladders, and other piece-picking methods are
traditionally used. Their versatile design allows for handling of a variety of items, ranging
from small items, such as individual auto parts or drugs, to larger bulky items like bicycles,
furniture or even mufflers. Faster travel, lift and lower speeds reduce order picking time, the
most labor intensive materials handling function. Their manoeuvrability in very narrow aisles
and high level “picking capabilities” enables the customer to take full advantage of limited
storage space.
Warehouses today are stocking many more SKUs (stock keeping units) due to consumer
demand for variety. There is an increasing need for a comfortable, efficient way to pick from
the second through fifth levels. The order picker is an ergonomic and economical solution for
order picking, an important part of warehouse activity, which can be up to 55 percent of
warehouse operating costs.
1.5.4 Hydraulic Lift

Fig: 1.5.4 Hydraulic Lift.

Hydraulic lift technology has a multitude of industrial applications, like construction and
transport. It is often implemented to operate heavy machinery or to move and lift heavy and
large objects like cars, dirt and shipping containers. Hydraulic lift technology can be found in
hydraulic jacks, forklifts, car lifts, among many other machines. Machines can use it to
provide the lift exertion (force) needed to produce work, such as moving another object.
Hydraulic lift technology is a critical aspect of engineering, without which many applications
would not be possible unless another technology existed to replace it. Automotive,
construction, avionics and shipping industries depend heavily upon it, and it has contributed
to a large part of the modern world as we know it.
Even automobile brakes use hydraulics. When you push the brake pedal, it pushes a small
piston in the brake master cylinder. The piston applies pressure on the brake fluid, which
transfers the pressure through the brake lines, forcing another set of pistons to force the brake
linings into contact with the brake drums on each wheel. The resulting friction of brake lining
against brake drum slows the car down, eventually stopping the car.
1.5.5 Pneumatic Tire Lift

Fig: 1.5.5 Pneumatic Tire Lift.

To start, pneumatic tires are similar to your regular car or truck tires, and are most commonly
used outdoors. There are two types, solid pneumatics and air pneumatics. The air pneumatics
are filled with air, while the solid pneumatics are made of rubber and more puncture proof. If
you have nails, rocks, or other sharp objects around the yard or workspace, you may want to
lean more towards the solid pneumatic option.
One of the biggest benefits of using pneumatic tires are their ability to absorb the unevenness
of terrain. This allows for a smoother ride, and less bumping and shaking. They are also
going to have a thicker tread, which provides traction to drive over loose and uneven surface.
The value of pneumatic tires in outdoor applications is that they ultimately increase your
uptime. Using the alternative, cushion tires outdoors will quickly lead to damage that will
mean you’re sitting and waiting on replacements. If you have a continual outdoor need, make
sure you work with your Toyota dealer to get the right pneumatic tire forklift for the job.

1.5.6 Container Handlers

Fig: 1.5.6 Container Handlers.

A reach stacker is a vehicle used for handling intermodal cargo containers in small terminals
or medium-sized ports. Reach stackers are able to transport a container short distances very
quickly and pile them in various rows depending on its access.
Reach stackers have gained ground in container handling in most markets because of their
flexibility and higher stacking and storage capacity when compared to forklift trucks. Using
reach stackers, container blocks can be kept 4-deep due to second row access.

There are also empty stackers or empty container handlers that are used only for handling
empty containers quickly and efficiently.

1.5.7 Narrow Aisle Forklift

Fig: 1.5.7 Narrow Aisle Forklift.

The Hyster VNA lift truck is designed for indoor use and is ideally suited for applications
such as large distribution centers and high density stacking and storing.
The Hyster V30-35ZMU series of lift trucks offers a host of options that guarantee you will
have exactly the truck your application requires. Options such as five chassis choices, three
operator compartment configurations, and either 48 or 72 volt systems are all available.
These options along with our advanced ergonomic design allow the operator to maintain
maximum productivity throughout an entire shift. And our superior energy efficiency makes
the V30-35ZMU very narrow aisle turret trucks cost less to operate and increase your
productivity.

1.6 Advantages

 Longer life
 Minimum noise level
 Suitable for indoor use
  Eco friendly operation
 It can be also used in hazardous areas
 Huge advantage is that it does not have fossil fuel cost
 The electric stacker has zero emissions and hence safe and healthy. It can also be
called green stacker
 Less maintenance due to minimum mechanical
 Small scale industries can also incorporate these stackers
 Minimum turning radius

1.7 Disadvantages

 Amount of load is limited

 Less speed

 Trained personnel needed to control

 They are usable only indoor purpose

 It requires electricity

 It can only go up to a limit

 Need Battery

 Need Electricity

1.8 Application

 Review the information below on how to use hand pallet trucks safely.
 Lead a discussion to help workers apply the information to your workplace.
 Briefly review the operating instructions for hand pallet trucks with the group. Ask
an experienced worker to demonstrate working with a hand pallet truck.
 Discuss hand pallet truck incident and injury prevention strategies. Use past
incidents to stress the importance of safe operation.
 Review the important points.
 Have workers take the True/False quiz to check their learning.
CHAPTER-2 LITERATURE
REVIEW
2.1 Hydraulic Forklift

Prof. Liai Pan, Chunshan He and Qiulei Du.

ABSCTACT

As a kind of industrial handling vehicles, forklift plays an indispensable role in people's life.
Nowadays, in order to meet the needs of the people, the types of forklift are more and more.
In this paper, based on already the basic parameters of the push forward forklift in the market,
the working device of the forklift has been introduced. And according to the calculation and
checking, the main structural parameters of the lifting oil cylinder have been determined. The
hydraulic system has been designed and calculated. The results of the paper have important
practical significance to design of work device of the forklift.

CONCLUSION

With the development of the logistics warehousing, industrial vehicle products to enter the
workshop, warehouse, supermarket and so on. As a kind of industrial vehicles, the current
types of forklift are limited, it can’t completely adapt to a variety of occasions. Most of the
time, standard forklifts are only suitable for a particular occasion, in addition to these specific
occasions; they may not very effective role. In this paper, based on already the basic
parameters of the push forward forklift in the market, the working device of the forklift has
been introduced. And according to the calculation and checking, the main structural
parameters of the lifting oil cylinder have been determined. The results of the study have an
important practical significance on meeting people's specific needs and improving the work
efficiency, etc.

2.2 Pneumatic Forklift

Prof. Admin

ABCTACT

Our undertaking work is “PNEUMATIC FORKLIFT” it can be utilized for lifting the vehicle
amid the supplant the wheel because of cut in current Manufacturing innovation, quicker and
simple innovation is inescapable. The pneumatic framework is utilized to the most critical
procedure of Industries and Harbour. Any work was done by the Pneumatic framework, Ex:
Lifting, Pulling, Pushing, Pressing, and so forth, above process can be made to effectively
vide by the Pneumatic framework. In this strategy for apparatuses, work is planned through
Air Pressure. So these procedures are utilized to a wide range of work. A wide range of
works can be effectively completed for this Air pumping weight making technique.
Pneumatic pump and Pneumatic barrel are utilized in this procedure. Pneumatic barrel’s
smash is increment and
abatement task completed in this procedure. For the most part, Pneumatic chamber tasks
depend on Pneumatic pump activity. Air is pumping to the Pneumatic barrel by utilizing
Pneumatic pump framework. It’s the manual task. Air is put away in the Pneumatic chamber.
So high pneumatic stress make in the barrel partition. In this time, the smash can move in the
barrel parcel. So slam can perform to our chose work.

CONCLUSION

Therefore pneumatic tires are ideal for the outdoor work where their shock absorption
qualities safeguard the health of the forklift operator. They have a thicker tread which gives
them the best traction on rough terrains. Since they are air-filled they play a big role in
cushioning the forklift against accelerated wear and tear from the bounce generated from
bumpy terrain.

2.3 Order Picker Forklift

Prof. Momcilo Miljus and Dragan Durdevic.

ABSTRACT

Warehouses and warehousing processes, as a significant component of the supply chains, are
places where the possibilities of rationalization are being continuously explored. Order-
picking, that generates main warehousing costs, is an especially interesting process in terms
of rationalization. As such, order-picking is a subject of permanent research in the field of
development and use of equipment, design, management, optimization, etc. One approach to
this goal is increasing the productivity of the workforce by using remote controlled forklifts
in the manually realized order-picking process in order to reduce order-picker’s engagement
time. This paper gives an overview of this technology with the evaluation of potential points
and the level of savings in order-picker’s labour time for a set of typical order-picking tasks.

CONCLUSION

By analysing presented technologies, it can be concluded that these are new solutions without
significant experiences in praxis. Mentioned manufacturers state their observations,
especially the ones referring to the range of favourable effects. It is clear that these states
should pass theoretical and practical audits, having in mind series of specificities related to
realistic tasks of order-picking, staff educations, appropriate information system support and
others. However, potential effects of this technology are very interesting for warehouse
system designers and it is required to have these technologies in mind when developing
alternative technological concepts of order-picking subsystem(s). Therefore, it is necessary to
perform series of research in this area, which can be related to the theoretical as well as to the
practical aspects. Some of them might refer to the work and time studies in different
environment/conditions (type of goods, orders’ patterns, path conditions, etc.), the analysis
of the specific strategies for goods assignment appliance, the use of additional devices and
equipment on OPF and etc. That way, the more qualitative bases for decision-making in
logistics’ system design would be acquired, and through them, support for more qualitative
level of supply chain solution.

2.4 The Economic Impact of Industrial Truck

Prof. Samantha Horton, Abdul Hameed Al-Shaebi, Nourma Khader, Husam Daoud Joseph
Weiss and Sang Won Yoon.

ABSTRACT

Forklifts touch almost everything that ends up in homes across North America. From the food
we consume to the cleaning products we use, the televisions we watch to the lawn chairs we
relax in, forklifts are integral parts of the supply chains that keep America moving. The
economic impact of forklifts in the U.S. is astounding, creating jobs in wide-ranging sectors
where operators are in demand and more goods are continually in need of manufacturing
(where their components are often hauled by forklifts).
But forklift manufactures themselves are key contributors the economy, even outside of the
residual markets and supply chains where forklifts are used. From manufacturing to sales and
delivery, forklift manufacturers are the people who move the capital equipment that keeps
everything else moving.
When Toyota Material Handling North America President & CEO Brett Wood was Chairman
of the Industrial Truck Association (ITA) in 2016, he led an initiative to hire Oxford
Economics to calculate the impact of the forklift industry on the overall U.S. economy.
Here are some industry facts related to the forklift industry in general:

 The forklift industry contributes the equivalent GDP of a small country like El
Salvador to the U.S. economy.
 The forklift industry pays $5.3 billion in annual taxes.
 The forklift industry employs more than 200,000 people.
 More than a half-million people drive forklifts every day.
 Ten percent of the workforce in the industry are Veterans, as opposed to seven
percent in all other industries.

The impact of the forklift industry can be defined beyond these statistics, but as a high-level
overview, these are fairly impressive numbers. The shared effort of Toyota Forklifts and our
competitors has a profound impact on the U.S. economy and the lives of people across North
America. And as the economic upswing leads to an even greater investment in capital
equipment, we’ll be a vital part of the domestic success to come.

CONCLUTION

The objective of this research is to study the forklift driving behaviour and explore its relation
to energy consumption and productivity (i.e., the average number of pallets moved per
operating hour) through conducting various statistical and regression analyses. Driver
behaviour related data such as travel speed, deceleration and acceleration rates are collected
from an actual warehouse. The experimental results illustrate the differences between drivers
who perform similar tasks, and demonstrate the consequences of different driving
behaviour’s on warehouse efficiency. For example, average speed is the most influential
factor that affects the energy consumption, while number of stops has the least impact.
Controllable experiments are suggested as future work to assign identical tasks to drivers, and
to avoid the impact of truck congestion and pedestrian on driver behaviour.
CHAPTER 3:- DRAWING OF
COMPONENT
Fig: 3.1 2D Drawing.
Fig: 3.2 Lifting Part.
Fig: 3.3 Body with Tire.
Fig: 3.4 Tire.
Fig: 3.5 Battery.
Fig: 3.6 Motor.
Fig: 3.7 Support for Battery.
Fig: 3.8 Pulley.
Fig: 3.9 Drafting Drawing.
Fig: 3.10 Assembly Drawing in 3D.
CHAPTER 4:- Outline of Work To
Be Carried Out In 6th Sem
In this project we have made design of the machine with the help of modelling software
comprising of various mechanism. This machine is not equipped with the mechanism
for sealing of one of the end of the neutral bar. So in future, design of this machine
might be extended for sealing of neutral bar at one of the end. One can work on that
mechanism with the same machine or with little changes in arrangements and structure
of the machine.
CHAPTER 5:- Reference
REFERENCE

1. Remote Operated Fork Lift Mechanism With Working Model

(Department of Mechanical Engineering Lovely Professional University Phagwara,

Punjab, India-14402 (2014))
Author - Kenneth B. Ackerman, Dr.R.N. Mall

2. Forklift for Industrial Purposes

(Department of Mechanical Engineering Rizvi College of Engineering Bandra (W) ,

Mum-50, Maharashtra, India (2020) )
Author - Saurabh S Shah, Mohd Husain A Sunasara, Pramit S Jain,
Zohaib Shirgaonkar

3. Design, Development and Modelling of Forklift

(Mechanical Engineering Department, RMCET, Ambav, Ratnagiri, India.-2014)

Author - Ugale Sachin S., Salvi Tushar S., Lanjekar Sachin S., Kshirsagar Prashant R

4. Human Powered Forklift

(Department. of Mechanical Engineering, SSPM’S college, Maharashtra, India-2018)

Author - Sachchidanand Nimankar, Nilesh Mahale, Aditya Mestry, Aniket
Morankar, Swaroop Nille