Managing Mechatronics Report

8/8/2019 Managing Mechatronics Report

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PROJECT REPORT ON

HYDRAULIC LIFT FOR LIFTING

HEAVY MATERIALS

SUBMITTED TO:-

JOHN GOULD

SUBMITTED BY:-

TRIBHUVAN SHARMA

STUDENT ID [2905083]

MANAGING MECHATRONICS

COURSE: - GRADUATE DIPLOMA IN MECHATRONICS

WELINGTON INSTITUTE OF TECHNOLOGY


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CONTENTS ABSTRACT.

SCOPE.

COMPONENTS REQUIRED.

SPECIFICATIONS.

BLOCK DIAGRAM.

PROJECT PLANNING

y BUDGET REPORT.

y CASH FLOW RATE.

y RESOURCE USAGE.

HAZOP study.

INTRINSIC FAIL SAFE DESIGN.

COMMISSIONING REPORT.

REFRENCES.


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ABSTRACT:-

This report is on a hydraulic lift whose functioning is predominantly governed

by a microcontroller. It can lift heavy loads e.g. heavy machinery, cars or trucks, or even a bigger group of 25 to 30 people from one floor of a building toanother.

SCOPE:-

Generally the commonly used lifts have got more mechanical components andwe all know that mechanical components are subjected to more wear and tear,

create unwanted heat due to friction and require more maintenance . Hydraulicsystem can generate more power and are more robu st as compared toconventional pulley block and tackle system used in lifts and when this systemis incorporated with electronic controls and programming it becomes moreefficient, cost economic, and requires less maintenance thus giving smoothfunctioning.

TIME:-It takes one week for initial research, planning and analysis. For designing and

building the actual lift it takes two weeks and one more week for implementation and testing the project. So it takes all in all 4 weeks to finish the

project.

COMPONRNTS REQUIRED:-

1. Microcontroller.

2. DC generator.

3. Hydraulic motor.

4. Flow control valve.


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5. Current sensor.

6. RPM transmitter.

7. Lifting cylinder with piston.

8. Alarm.

SPECIFICATIONS:-

1. Microcontroller It is the heart of the whole assembly because it contains all the data and

programmes in its memory. It is connected to all the input and output devicesand gives commands to all the components to do their desired actions. E.g.Arduino. It can be programmed in different ways as per desired by theoperator.

2. DC generator.It is connected to the hydraulic motor and provides torque to the shaft of themotor. It acts both as motor and generator.In the lifting operation, the DCgenerator acts as a motor and drives the hydraulic motor in such a rotational

direction that hydraulic fluid is conveyed from storage tank through thecontrol valve arrangement and into the hydraulic cylinder. In the loweringoperation, the piston conveys, under the influence of the load, the hydraulicfluid back through the control valve arrangement and into the storage tank.The hydraulic motor operates in motor operation and drives the DCgenerator, operating as a generator.

3. Hydraulic motor.

Its function is to pump the liquid up from the storage tank into the hydrauliccylinder during lifting operation and pump it back to the storage tank whilelowering operation.


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4. Flow control valves.It controls the amount of fluid that has to be pumped into the hydrauliclifting cylinder. It gets its signals from the microcontroller and supplies a

particular amount of fluid thus governing the speed of the lift.

5. Current sensor.It creates an interface between the input circuit and DC generator and itassures that the predetermined value of the tor que of the DC generator ismaintained.

6. RPM transmitter.

An rpm transmitter is coupled to the shaft of the hydraulic motor, whichtransmits a signal corresponding to the rpm of the hydraulic motor to thelifting mechanism control. The lifting mechanism c ontrol comprisesregulation means, which, depending on the determined rpm, influences theexcitation of the DC generator in such a way that a predetermined desiredrpm can be maintained in motor operation, as well as in generator operation.

7. Lifting cylinder with piston.

It is the hydraulic cylinder with a piston with which the lifting cage isattached. So when the fluid under pressure lifts up the piston the lifting cage

gets lifted up.8. Alarm.

Alarm in a hydraulic lift is a fault indicator which is incorporated in theoutput circuit which rings up in any kind of malfunctioning and unexpectedoperation of the lift.


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Block diagram:-

Lifting cage

Storage tank

CPU

Microco

ntroller

Input circuit

Keyboard

FlowCont

rolvalve

Currentsensor

Output

circuit

DC

motor

Hydraulicmotor


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Project planning


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Budget report:-


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Resource usage:-


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HAZOP STUDY:-

HAZOP study is well-proven structured team-based method for hazardidentification at process design completion or for planned modifications. Thetechnique makes detailed examination of the process and engineeringintention of new or existing facilities to assess the hazard potential of operation outside the design intention, or malfunction of individual items of equipment and their consequential effects on the facility as a whole.

HAZOP is led by an experienced facilitator. A hazard that has beenoverlooked can have a significant impact on the overall success of theventure. An effective HAZOP provides the most penetrating design review,

covering safety, environment, operations, and maintenance .HAZOP ensures that potential deviations from intended design function areidentified and corrected and actions for necessary process or instrumentationimprovements can planned.

PURPOSE, OBJECTIVE AND SCOPE OF THE STUDY:

y To check the safe operation of the system.

y To prevent the hazard that may occur.

y To reduce the impact on environment.

y Develop safety measures to deal with emergency cases.

HAZOP team members.

1. Mechanical engineer.

2. Electronics engineer.

3.

Maintenance engineer.


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Emergency shutdown:-

When the lift starts deviating from its normal working cycle resulting in somesevere damage to anything, it has to be shutdown and stopped to the safest

position i.e. (nearest floor) to it. This can be done by an emergency shutdown button which when pressed stops the system instantly.

The emergency button when pressed will activate the alarms and another signalgets automatically passed to the microcontroller when then stops the lift to itssafest mode.

Fire alarm and separate pump provisions.

Chances of fire as we have discussed are very less due to less fri ction and lessmechanical components. But still if there is any the fire alarm is provided whichwill automatically stop the lift and open the doors to its safest floor and will alsoactivate the fire extinguishers.

Also if in any case if the hydraulic pump stops pumping fluid there is a provision of a separate pump which will keep pumping fluid to the hydrauliccylinder and the lift will keep on moving.

Along with these basic safety requirements we can also use an RPMtransmitter to the shaft of hydraulic motor. An RPM transmitter transmitsa signal corresponding to the RPM of hydraulic motor to themicrocontroller and it thus regulates the excitation of DC motor depending upon the return signal given by microcontroller. Finally ithelps in maintaining desired RPM in motor and generator operation,reduces any chances of trouble shooting with the motor operation andthus making our lift performance more smooth and our design safer.


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Commissioning report:-

Commissioning is a process for achieving, verifying, and documenting the performance of a facility to meet the operational criteria of the contract designdocuments. Its intent is to furnish the Owner with a high degree of assurancethat the equipment and systems have been installed in the pr escribed manner and will operate according to the performance guidelines .

Purpose: - Commissioning of a current sensor in hydraulic lift.

Model description:-

High linearity and accuracy. Capable of switching 1.5 HP to 2.5 HP @ 120 v AC to @$) v AC. Operating range is 20 amps to 100 amps. Fast response and low temperature drift. Adjustable mounting bracket for installation flexibility. Override protection and current feedback control system. Visual indication for output status(LEDs) Hysteresis error +_20mv. Operating temperature -10degreeC+80degreeC Response time is < 5 s.

Price: $ 50 when ordered as part of a system.


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I nstallation points to be checked:

Installation Points to be checked Complete Comments

Check whether the system is turn on.Check whether the power supply is working.Check whether all the wires are connected properly.Check whether sensor pins are connected properly.Check the output of the sensors.Check the output of microcontroller Check whether GSM modem is workingReplace the faulty components

I hereby undertake that the System referenced above has been commissioned byme, in accordance with the prescribed commissioning report above and that Iam satisfied that all of the installation points specified have been correctlyfollowed / checked.

Tribhuvan Sharma.

10- oct- 2009

References:-

y www.freepatentsonline.com y www.directindustry.com

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Managing Mechatronics Report