Internship Report 2019

Jimma University
Jimma Institute of Technology

Faculty of Mechanical Engineering

Internship Report
Hosting Company: ADAMA MOENCO
Project Title: Design of Mechanically Operating
Ope Gearbox Hoist
Internship Duration- March 15, 2019
2019- June 15, 2019

By: Jiregna Teka ID: RU1609/08

Mentor: Mr. Sewayew
Company Supervisor: Mr. Neb
Nebiyou
October 8,
8 2019

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Declaration
I hereby declare that this internship report and project paper is my original work except some
references and manuals used. The References used are fully cited. The paper has been
submitted to Jimma institute of technology faculty of mechanical engineering.

Name Signature Date

Jiregna Teka __________ ________________

Advisor approval

This is to certify that the above statement made by the candidate is correct to the best of my
knowledge and belief. This paper has been submitted for presentation with my approval.

Name of Advisor _______________________________ Signature ______________

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Acknowledgement
Firstly, I would like to thank my God for allowing me to be successful on my internship and
pass through difficult times in my internship time. Secondly, my adviser Mr. Sewayew helps
me on selecting my project title and gave me information on how to write a report. I also
would like to thank MOENCO, the company which gave me the opportunity to have my
internship time with them. and I greatly pleased to say MOENCO workers not only for their
hospitality but also their positive thinking to let me know what I asking, there approach was
so good for me to feel free when I was on work in the company totally they were not only
MOENCO workers but they were also as a good friend for me, specially Shiferaw who is the
foreman of unit rebuilding shop and Meles who is the foreman of general service. Generally,
Gratitude is the hardest emotion to express and one often does not find adequate words to
convey that entire feeling. It has been my good fortune to come across so many good hearted
people during my project activity, although it is as good as impossible to include the names of
each of them here. I gratefully thank MOENCO worker for their invaluable help and guidance
in adding of technical general knowledge. Finally, I would like to thank the service manager
Mr. Sendeku for helps me by material and branch manager of MOENCO Mr. Nebiyou.

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Executive Summary

This internship report document is based on the four-month long internship program that I had
successfully completed in MOENCO Adama branch. Totally this report contains four chapters.
Under the first chapter I briefly describe background of the company that’s includes brief history
of the company, main services, main customers, organizational structure, work flow, mission,
vision and value of company.
The second chapter of the report discusses about overall internship experience and benefits that’s
briefly talks about the section of the company I have been working with, work flow and work
tasks and also the types of tools, methods and techniques I used to perform my work task. This
chapter also talks about major problem while performing the work task and their proposed
solution then it concluded with overall benefits I have gained from the internship in terms of
different aspects.
The third chapter of this report is discussing about the project I done for the company problem
that is design of mechanically operating gearbox hoist which is used for lowering and lifting all
vehicle model gearbox that is reduce human effort and time with its innovative simple design
and also devoting to find the solution which is the main challenge in MOENCO. This designed
gearbox hoist is capable of lowering all types of gearbox having maximum weight of 1471.5N up
to the ground by using only one man power that is reduce man power spent on lowering and
lifting of this gearbox and also time. Totally I done this project to make it clear and
understandable as much as possible by describing it clearly starting from identifying the problem
and its justification, describe the objective & methodology followed by design analysis then
finalizes by fabrication of prototype of the hoist. The design analysis is done by taking the
analysis of each component and assembly from the software CATIA. The working principle and
cost analysis of my project is also discuss clearly. The material for each parts of the hoist is
selected to make the product durable, efficient and safe with total cost of 6350 birr.
The last chapter is finalized by general conclusion and recommendation of the internship.

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Table of Contents
Declaration……………………………………………………………………………………….ii
Acknowledgement ......................................................................................................................... iii
Executive Summary………………………………………………………………………………iv
List of Figures ............................................................................................................................... vii
List of Tables ............................................................................................................................... viii
CHAPTER ONE ............................................................................................................................. 1
BACKGROUND OF COMPANY ................................................................................................. 1
1.1. History of company ............................................................................................................. 1
1.2. Main product and service .................................................................................................... 5
1.3. Main customers or End users of its product or service ........................................................ 7
1.4. Overall organization structures ............................................................................................ 8
1.5. Work flow of the company .................................................................................................. 9
CHAPTER TWO .......................................................................................................................... 10
THE OVERALL INTERNSHIPE EXPERIENCE ....................................................................... 10
2.1. The section of company I have been working in ............................................................... 10
2.2. The work tasks I have performed in each section .............................................................. 10
2.3. Engineering Methods, Techniques and Tools For Executing Tasks.................................. 18
2.3.1. Engineering methods and techniques for executing ................................................... 18
2.3.2. Tools I have been performing my work in the servicing shop ................................... 19
2.4. Challenges and problem I have been faced while performing work tasks ........................ 21
2.5. Measure I have take in order to overcome these challenge ............................................... 22
2.6. Overall Internship benefits ................................................................................................. 22
2.6.1. In terms of improving my practical skill...................................................................... 22
2.6.2. In terms of updating my theoretical knowledge .......................................................... 22
2.6.3. In terms of improving team skill.................................................................................. 22
2.6.4. In terms of improving leadership skill ......................................................................... 23
2.6.5. In terms of understanding about work ethics issues, industrial psychology and related
issues ......................................................................................................................................... 23
2.6.6. In terms of entrepreneurship skill ................................................................................ 24
2.6.7. In terms of improving interpersonal communication skill........................................... 24
CHAPTER THREE ...................................................................................................................... 25
DESIGN OF MECHANICALLY OPERATING GEARBOX HOIST……………………..…...25
3.1. Problem statement and Justification .................................................................................. 25
3.1.1. Problem statement ....................................................................................................... 25

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3.1.2. Justification…………………………………………………………………………..26
3.2. Objective of the project…………………………………………………………...………26
3.2.1. General Objective……………………………………………………………………26
3.2.2. Specific Objective……………………………………………………………………26
3.3. Scope of Study……………………………………………………………………………26
3.4. Conceptual Design………………………………………………………………………..26
3.5. Working Principle………………………………………………………………………...27
3.6. Limitation…………………………………………………………………………………27
3.7. Methodology ...................................................................................................................... 28
3.7.1. Material selecting ........................................................................................................ 28
3.7.2. Design Analysis of Main Components ....................................................................... 28
3.7.3. Fabricating process of the prototype ........................................................................... 52
3.7.4. Cost analysis ............................................................................................................... 53
CHAPTER FOUR......................................................................................................................... 54
GENERAL CONCLUSION AND RECOMMENDATION ........................................................ 54
4.1. Conclusions ........................................................................................................................ 54
4.2. Recommendation ............................................................................................................... 55
Reference .................................................................................................................................. 56
Appendices ................................................................................................................................ 57

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List of Figures

Figure 1: Logo of MOENCO ........................................................................................................ 1

Figure 2: Toyota light vehicle ........................................................................................................ 3
Figure 3: Location of the company ............................................................................................... 3
Figure 4: Head office of Adama MOENCO................................................................................... 4
Figure 5: Overall organization structure......................................................................................... 8 8

Figure 6: General work flow diagram of the company. ................................................................. 8 9

Figure 7: Repair and general service section ................................................................................ 10 10

Figure 8: Engine Overhauling ...................................................................................................... 13 13

Figure 9: Differential Overhauling ............................................................................................... 13 13

Figure 10: Transmission and transfer case Overhauling .............................................................. 14 14

Figure 11: Starter motor overhauling ........................................................................................... 14 14

Figure 12: chassis repair shop and body shop .............................................................................. 15 15

Figure 13: Electric repair and service shop……………………………………………………..16

Figure 14: Intelligent tester .......................................................................................................... 16
Figure 15: Wheel alignment shop……………………………………………………………….17
Figure 16: Open wrench and Combination wrench ...................................................................... 19
Figure 17: Close wrench and Adjustable wrench ......................................................................... 19
Figure 18: Socket and ratchet ....................................................................................................... 19
Figure 19: Screw driver and filer gauge ....................................................................................... 20
Figure 20: Hammer and snap ring remover .................................................................................. 20
Figure 21: Air compressor............................................................................................................ 20
Figure 22: Power wrench and SST tools ...................................................................................... 21
Figure 23: Injector nozzle tester and laundry ............................................................................... 21
Figure 24: Gearbox removing ...................................................................................................... 25 6

Figure 25: Mechanically operating gearbox hoist…………………...…………………………..27 8

Figure 26: 3D CATIA design of Bed Cantilever Beam ............................................................... 29 0

Figure 27: 3D CATIA design of Beam ........................................................................................ 34 5

Figure 28: 3D CATIA design of Caster Beam ............................................................................. 38 9

Figure 29: 3D CATIA design of Worm gear shaft ....................................................................... 48 9

Figure 30: 3D CATIA design of pillar ......................................................................................... 49 0

Figure 31: Fabrication process of my project prototype .............................................................. 52 3

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List of Tables
Table 1: Indian Standard designation of steel ............................................................................... 30 1

Table 2: Sandard Wire rope table ................................................................................................. 43 4

Table 3: Actual and Equivalent length of pillar............................................................................ 51 2

Table 4: Cost analysis ................................................................................................................... 53

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CHAPTER ONE
BACKGROUND
ACKGROUND OF COMPANY
1.1.History of Company
Where and When the MOENCO S Story Began
The Motor and Engineering Company (MOENCO) was established in January 1959 in the heart
of Addis Ababa, around the area commonly known as Mexico, a small Garage with a capital of
200,000 Ethiopian birr. MOENCO was founded by Mr. Y.D. Lappine in small
sm rented house, His
far sighted vision became reality with the help of other resourceful people such as Ato Minasseh
Lemma, governor of the national bank of Ethiopia and the boss of imperial Insurance Company.

Figure 1: Logo of MOENCO

Nine years later (1968) with Inchcape’s encouragement and investment MOENCO took over the
TOYOTA Franchise business. For Ethiopia when Inchcape which is London based international
organization became a major shareholder spent a considerable amount of capital. This was the
milestone Movement in the firm’s journey to become the MOENCO of today. In addition to
TOYOTA business, at different times MOENCO used to represent GENERAL MOTORS for
various type of vehicles and trucks of American and England like
like Ingersoll-Rand,
Ingersoll WABCO,
Pettibow, Universal, Dupont, and General tire, Fregidire, Zanussi and Thomas Delarue .

MOENCO becomes a great experience and makes it to focus on people, service and innovation
over the past six decades. It is the second oldest TOYOTA
TOYOTA distributor in the world, after having
won franchise in 1968 and not only this Ethiopia was the first African country to imported
TOYOTA brand vehicles through MOENCO over six decades ago. Those first vehicles were
land cruiser donated to the emperor Hailesellassie by the kingdom of Japan because of Ethiopia
and Japan has been good relationship at the time
time.

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MOENCO Today
In 2011, MOENCO is the largest automotive company in the country representing over 20
brands. MOENCO has both in terms of size and in terms of modernization of its services shops
and part distribution centers which display passion for creating the ultimate customers
experience and profit. The company today has a close relationship with TOYOTA Motor
Corporation. MOENCO sales, parts and service other brands in addition to TOYOTA. It is
currently imports like Daihatsu vehicles, KOMATSU construction equipment, Suzuki bikes,
LISTERPETTER diesel engines case, new Holland and etc. Now a day MOENCO exports
coffee and other products rather than import.

Branches
Hawassa Branch: first MOENCO branch located 275 KM south of AA. Providing quality
service and Genuine Toyota parts .became operational in August 1998

Bahirdar Branch: second MOENCO branch, located 558 KM north of AA. Providing quality
service and genuine parts. Became operational in May, 2004

Adama Branch: third MOENCO branch, located 99 KM east of AA. Providing quality service
and genuine parts. Became operational in January 2010

Diredawa Branch: forth MOENCO branch, located 500 KM from AA. Providing quality
service and genuine parts. Became operational in 2014.

Mexico parts retail shop: became operational in January 2008.

Kality Machinery Branch: a new construction and Agricultural machinery branch became
Operational in 2013. Now a day MOENCO has seven operational sites and 13 major dealers
across the country which dealers are gained a benefit of 25% of a sale and parts profit.
MOENCO provides different education programs ranging from technical and basic skills training
to highly specialized development programs. It gives higher education, graduate and post
graduate programs for its force. Currently the company employed more than 1500 permanent
employees and has annual turnover of many billions of Ethiopian birrs. MOENCO has its Owen
written constitutions which is written in English and Amharic language for the purpose of
employee’s agreement.

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Motor and Engineering Company of Ethiopia Adama Branch

MOENCO Adama branch was established on January 2003 E.C with an initial investment of birr
30 million under commercial law of Ethiopia. Now at this movement in the company there are so
many employers. The world class purpose built customer service center embraces vehicle part
sales and service facilities in one building (3S) MONECO is the Sole and Exclusive Distributor
of countries class brands; to mention few: some of those Yaris, Corolla , Land cruiser,
Hilux, Coaster, hardtop Hiace, Avensis, Vitz, Porte, Land cruiser, Prado Land cruiser and
hardtop Land cruiser pickup

Figure 2: Toyota light vehicle

Location of the company

The motor and engineering company of Ethiopia Adama branch is located in Adama town 78
KM from the capital Addis Ababa city

Figure 3: Location of the company

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MOENCO Adama branch is located in a convenient area and rests on 20,000m2. It renders
quality service to customers in Adama and surrounding locations.

Figure 4: Head office of Adama MOENCO

Mission, Vision and Values of the company
I. Mission
 To strive customer oriented national company that is socially responsible and can bring
growth though delivery of better products and services.
 To provide safe and sound journey.
 To developing various new technologies of energy saving and diversifying energy
sources.
 Most important issue in priorities of the company is working toward creating a
prosperous society and clean the country.

 Minimizes time for the service of Toyota vehicle.

 Providing Excelling service and many magic moments by customer friendly service,
advisor, sales people, Toyota certified technician and support staff
 To meet and exceed the expectation of its existing and future customers by distributing
world class brand products all over the Ethiopian market and giving support with
genuine spare parts and quality service to ensure trouble-free with the least impact to
environment.

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II. Vision
To be the most customer centric distribution of vehicle and equipment for the construction,
Agriculture and industry sectors in Ethiopian with unparalleled after sales service supported by
state of art technology and skill manpower
 To be competent in nations market  To be the most respected and
with better efficiency. successful enterprise.
 Delighting customers  The best people with best
 Wide range of products technology

III. Values

MOENCO being an affiliate company of INCHCAPE PLC, shares same set of values stated here
under.
 winning Together  Passionate about customer
 Treating every coin as own  Caring for our environment
 Integrity without compromise  Respect for each
 Pioneering new ideas

1.2.Main Product and Service

MOENCO is the largest automotive company in the country, representing over 20 brands of light
duty vehicles and heavy duty (construction and agricultural) machineries MOENCO has grown
both in terms of size and in terms of the modernization of its service shops and part distribution
centers. Those display a passion for creating the ultimate customer experience.

Main Service of MOENCO

MOENCO represents TOYOTA one of the great Automobile Company of the world. The main
reason that makes MOENCO the great organization is its providing of different service for the
customers. Services that is given by MOENCO are:

 PDI(pre delivery inspection) service

 Free service check-up

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 Express maintenance service
 Periodic maintenance service
 General repair
 Body and paint repair service
 Annual vehicle inspection
 Towing service

i. PDI Service

Before delivering a new vehicle to the customers the pre delivery inspection is done. The job of
PDI staff includes removing the protective materials applied to prevent possible damage on the
vehicle during transportation from the supplier to the distributor, inspection of mechanical status,
body parts and any paint defects on each and every vehicle, installation of d/t accessories to
confirm the finished condition and guarantying the quality standard that TOYOTA, DIAHASTU
& LEXUS stand for.

ii. Free Service Check –up

In MOENCO there is free service check –up for vehicles that are purchased from MOENCO in
every 1000 KM & 5000 KM this makes the customers feel safe with their properties & satisfy
with their new vehicle. Only the customers have to pay replacement of lubricant and filters.

iii. Periodic Maintenance service

Every TOYOTA, DAIHASTU & LEXUS vehicles have to be periodically maintained in every
5000 KM or by the intervals of 3 months. Periodic maintenance will insure reliability, high
resale value, long life and maximum performance.

iv. Express Maintenance Service

This service is done for vehicles with miles age up to 50,000 KM. The service is given by using
the best & most advanced automotive equipments and the service provided by their qualified
technicians enable them to delivers TOYOTA`S quality service to their beloved customers .

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v. Body and Paint Repair
MOENCO by teaching the proper fundamentals of body & paint through a continued in – house
and overseas training program & using the state of the art equipment manages to develop fully
fledged body and paint technicians who can correctly trouble shoot and carry out major & minor
body & paint repairs to mint condition.

vi. General Repair Service

MOENCO service centers also provide general repair service for all sophisticated general
mechanical & electrical system on all TOYOTA, DIAHASTU & LEXUS vehicles. Their general
repair service comprises of units over hauling (like engines, automatic transmission & manual
transmissions transaxles, fuel injection pumps, differentials, steering gear box, vane pumps,
starters, alternators etc) and diagnosis & repair of any malfunctions on the vehicle using the state
of – art equipment & tools available in the service centers.

vii. Annual Inspection

The Ethiopian transports authority decides for all vehicles have to be annually inspected for
safety of the human life & economic disaster this inspection carried out in the designated vehicle
inspection center. They provide inspection service to all TOYOTA, DIAHASTU & LEXUS
vehicles.

viii. Towing Service

MOENCO also provide towing service (dragging of a car) to assist our customers in the event of
vehicle collapse or malfunction.

1.3. Main Customers or End users of its Product or Service

The customers could be governmental or non-governmental organizations. From those we have
listed below some.-Different vehicle owner individuals-governmental organizations-non-
governmental organizations-construction companies-Federal water works enterprise- Oromia
water and mineral enterprise-agricultural based industries, etc.

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1.4. Overall Organization Structures
MOENCO Company is currently organized in four divisions and nine Departments that enable to
its customers and avail modern after sales facility; it has established four branches in four
corners of the country in the last seven years. Following the establishment of branches and sub-
dealers network, our customers have been privileged to have easy access to genuine spare part
sales and maintenance services provided by the company. These four divisions and nine main
departments and their sub departments are explained in the overall organization structure.

Branch Manager

Security guard
section
Finance and Service manager
Administration
section
Parts and
Accountant Warehouse section
Junior Accountant
Cashier warehouseman
Senior sales person
Sales person

Customer’s unit Repair shop Forman

service Body and paint shop
head Forman
Lead technician
Senior service advisor Senior Technician
Service advisor Technician
Junior Service advisor Lead body technician
Senior body technician
Body technician

Figure 5: Overall organization structure.

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1.5. Work Flow of the Company

The general work flow of the company includes the whole processes done while one car is being
serviced. Most of the time governmental and NGO’s cars are serviced at the company which
need a fastest service time. For this reason the work is divided into different sections.The figure
below shows the general work flow diagram of the company.

Vehicle Vehicle Cost

Reception Inspection Estimation

Vehicle delivery Quality control Service section

- Mechanical Repair

- Body and Paint

- Engine maintenance

Figure 6: General work flow diagram of the company.

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CHAPTER TWO
THE OVERALL INTERNSHIP EXPERIENCE

This part contains about the overall experience of internship that means available work sections I
have been working in the company, work of tasks executing, engineering methods, tools and
techniques using while performing my work tasks, my performance on the accomplishment of
tasks, challenges I have faced and measures that I have taken, the overall internship experience
and benefits related to different aspect.

2.1.The Section of Company I have been working in

There are many sections of work in this company, the following are among these
 Repair section  Electric system servicing section
 General service section  Express service section
 Unit rebuilding section  Wheel balance and alignment section
 Body and painting section
2.2.The Work Tasks I have Performed in each Section
i. Repair and General Service Section
In both sections I have been perform the same activity, but the vehicles that encounter to the
accident are the concern of repair section.

Figure 7: Repair and general service section

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The activity carried out in these sections can be

 SERVICE TYPE A

• This type of service is recommended for a car which travels 5000KMs.typeA service is
the easiest and cheapest service type.

It includes: -

 Replacement of air cleaner

 Replacement of engine oil with oil filter

 Replacement of steering knuckle, steering linkage

 Inspection of brake pad, discs and drum brakes, battery, tightening propeller shaft,
bolt, nut, front and rear suspension.

 External linkage if any

 Lubrication of propeller shaft

 SERVICE TYPE B

• This type of service is recommended for a vehicle which has traveled 10,000KMs. It
includes the following tasks including all type A, service.

 Replacement of steering knuckle and steering linkage

 Inspection of brake disc run out, ball joint and dust covers, Brake pedal and parking
brake, brake fluid and lines, clutch fluid, power steering fluid

 Inspection of fuel filter, water sedimentary.

 SERVICE TYPE C

• This type of service is recommended for a vehicle which has traveled 15,000 KMs.

• This type of services is a little bit complicated and includes the following tasks including
type B Service

 Inspection of wheel bearing grease

 Inspection of different gear oil

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 SERVICE TYPE D

• This type of service is recommended for a vehicle which has travelled 40,000 and
80,000kms.

This type of service is the most complicated and includes the following tasks including type C
service.

 Inspection of drive shaft boot

 Replacement of brake fluid, engine oil, differential and gear box oil

 Greasing the wheel bearing

 Inspection of valve clearance ,replacement of timing belt

 Check and adjust idle speed, manual transition, exhaust pipes and mountings, fuel tank
line etc.

ii. Unit Rebuilding Section

A. Engine Overhauling

In the company I have been disassemble the removed engine from the vehicle, wash the
disassembled parts by petrol and inspect the defective parts. Such as cylinder head, valves, valve
lifter, valve shim, valve spring, camshaft, crankshaft, crankshaft bearing, timing belt, piston ring,
piston, connecting rod, short block, cooling system components and lubrication system
components. If the above parts are defective, they should be reconditioned or replace. And
reassemble the engine. Then remount the engine on the vehicle and test the oil pressure by using
oil pressure testing gauge. If it is out of the specification remove the engine and check the oil
pump. If it is out of specification replace it.

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Figure 8: Engine Overhauling

B. Differential Overhauling

I have been disassembling the removed differential and wash the disassembled parts by petrol.
Inspect the defective parts. Such as drive pinion gear, ring gear, side gear, side pinion gear, front
small and large bearing, collapse, side bearing and back lash adjusting nut. If the above parts are
defective, they should be replaced. And reassemble the differential.

Figure 9: Differential Overhauling

C. Transmission and Transfer Case Overhauling

I have been disassemble the removed transmission and transfer case, wash the disassembled parts
by petrol and after washing the transmission housing wash by laundry again. And inspect the
defective parts. Such as input shaft and its gear, countershaft gear, output shaft and its gears,

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synchronizers, sleeves, hub, forks, and shifting liver shafts and the transfer shaft and gear. If the
above parts are defective they should reconditioned or replace.

Figure 10: Transmission and transfer case Overhauling

D. Alternator Overhauling
I have been disassemble the alternator and inspect the abnormal parts, if there is replace or
recondition to specified condition, Depending on the service manual.

E. Starter Motor Overhauling

I have been disassemble the starter and inspect the abnormal parts, if there is replace or
recondition to specified condition, Depending on the service manual.

Figure 11: Starter motor overhauling

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iii. Body and Paint Shop
Body and paint shop has its Owen Forman and work shop. They have also their Owen
procedures and techniques to repair the vehicle. There are two sub sections. These are express
section and general section. The work of the two sections almost the same. The work I have
been performed in these shops can be

Repair body; the damaged body part repair by off dolly, on dolly and washer welding.

Repair chassis: preparing the chassis for measuring, measuring the chassis bendiness, repair
depends on the measured value by pulling and pushing.

Figure 12 : chassis repair and body shop

Painting: This shop is divided in three shops. One is the chemical to be mixed shop which is the
different color fixation is being done from their store in this shop by using the appropriate
software and technician.
iv. Electric System Servicing Section
In this shop, most of a vehicle`s electrical systems are maintained or replaced by a new one. The
work I have been executing in this shop was:-
 replacing dead battery  check sensor, actuator and ECU condition
 check and replace the glow plug using intelligent tester
 check and replace the head lump and  Maintain the wires of display gauges
combination lump

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Figure 13: Electric repair and service shop

The Procedure we have been using Intelligent Tester

 connect the intelligent tester and vehicle side data link connectors with the data link cable
 turn the vehicle ignition switch ON
 press the intelligent tester power switch to turn the power ON
 after the opening screen is displayed automatically switches to the Onboard/off board check
screen
 When using the intelligent tester as the OBD functions, touch auto or manual on the onboard/
Off board screen

Figure 14: Intelligent tester

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v. Express Service Section

In express maintenance shop, service We have been done for vehicle mile age up to 50,000km.in
this shop there is two technician, one main technician which have more job experience and one
supporter technician. Depending on the kilometre the gone the main service done in these shop can
classify in to two A-service and B-service
vi. Wheel Alignment Procedures
Before performing the wheel alignment operation you have to check the inflation of the front tire or
pressure of the tire and if it’s not correctly inflated you have to full the pressure of the front tire. To
perform the alignment we also check the model of the vehicle because of the alignment is
performed according to the model of the car to get the better alignment.

Figure 15: how to adjust the vehicle on lift and how to adjust a wheel alignment on screen
To align the wheel alignment:-
 Take the vehicle to the lift position
 Adjust the flexible cable to the lock position
 Roll the vehicle on to the flexible cable then unlock the flexible cable
 Depress the brake pedal and hold by the equipment there
 Steer the steering as shown direction on computer screen then fix the
steering wheel at the normal position. i.e straight a head

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By using camber, caster and toe angle we can adjust the wheel alignment
We use Camber -to brought the arrow on the computer screen that are opposite in
directions in to the same direction.
We use Caster- to correct the arrows in the same range to the needed degree.
Toe - to correct toe in or out.
If the vehicle uses the steering knuckle joint you can adjust the camber, caster and toe by seeing on
the computer screen by using different SST tools but when the vehicle is connecting rod joint form
we can’t consider about the caster and camber but we consider about the toe. We adjust the toe only
for cars having these forms.

2.3. Engineering Methods, Techniques and Tools For Executing Tasks

2.3.1. Engineering methods and techniques for executing
In working section, all the above work tasks are performed according the standard instruction of
manuals formulated by Toyota Company. And these guidelines contain many engineering methods
and techniques. Some of the engineering techniques and methods are:
 Safety: - The Company provides a standard work wearing and putting a rule that all mechanics
should wear at work with gloves. Also each mechanics have their own table and box for putting
their own work tools.
 Cleaning: - there are cleaners which work equal time as mechanics.
 Reuse of replaced materials: - The other methods I have seen how they use the wasted materials
and oils. For instance the replaced engine oils are collected and sold to the outside customers.
 Automation:-In this section most of the tasks are performed by machines, for example :use of
compressor for power wrench, for cleaning: use of hoist machine for moving gearbox ,
engines& other heavy machines: use of lifting machine driven by electric motor for
transportation of heavy machines: use of press machine and other simple machines which
reduces human labor.

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2.3.2. Tools I have been performing my work in the servicing shop

In working section there are various tools such as, Hand tools:- Socket, Universal Joint (Socket
Wrench Set), Extension Bar (Socket Wrench Set), Ratchet, Boxed Wrench, Opened Wrench
(Spanner), Adjustable Wrench, Screwdriver, Needle-Nose Pliers, Slip-Joint Pliers, Cutting Pliers
(Nipper), Hammer, Gasket Scraper, Centre Punch and Pin Punch are hand tools. Wrenches: are
used to turn screws, nuts, and bolts with hexagonal heads. There are three types of wrenches. Open
end, box (closed) and combination

Figure 16: Open wrench and Combination wrench

Adjustable wrench is often used where the exact size wrench is not available or when a large
nut, such as a wheel spindle nut, needs to be rotated but not tightened.
Socket fits over the fastener and grips the points and/or flats of the bolt or nut. The socket is
rotated (driven) using either a long barer a ratchets.

Figure17: Close wrench and Adjustable wrench

Ratchet used to rotate a socket. A ratchet makes a ratcheting noise when it is being rotated in the
opposite direction from loosening or tightening. A knob or lever on the ratchet allows the user to
switch directions.

Figure18: Socket and ratchet

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Filer gauges: used to adjust the valves & to measure the air gap between assembled parts
Screwdriver a flat-tip (straight blade) screwdriver. The width of the blade should match the
width of the slot in the fastener being loosened or tightened. Phillips screwdriver: Due to the
shape of the crosshead screw and screwdriver, a Phillips screw can be driven with more torque
than can be achieved with a slotted screw.

Figure19: Screw driver and filer gauge

Hammers are used to force objects together or apart. The shape of the back part of the hammer
head (called the peen) usually determines the name.
Snap ring remover; used to remove rings from the assembly.

Figure20: Hammer and snap ring remover

Air tools:-air compressor and power wrench (impact wrench) are air tools.
Air compressor a shop air compressor is usually located in a separate room or an area away
from the customer area of a shop. The longer an air tool can be operated in the shop without
having the compressor start operating.

Figure21: Air compressor

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Power wrench (impact wrench) an impact wrench, either air (pneumatic) or electrically
powered, is a tool that is used to remove and remount fasteners. The air-operated 1/2 in. drive
impact wrench is the most commonly used unit.

Figure22: Power wrench and SST tools

Measuring tools Torque Wrench, Venire Calipers and Micrometer are measuring tools.
There is also Auto lift, Car jack and laundry

Injector nozzle tester and laundry

Figure23: Injector nozzle tester and laundry

2.4. Challenges and problem I have been faced while performing work tasks
During my internship period I have been faced some problems. The company has no good
attitude in previous student. I have been faced in economical problem. Another challenge that I
have been faced during my internship period was working without safety material like without
safety boots and faced with the problem of internet and also this problem limit me to upgrade my
theoretical knowledge. In this company there is no hoisting machine which is used for lowering
and lifting gearbox of all vehicle models while removing and remounting gearbox from vehicle.
Actually the company have a transmission jack that used for lowering and lifting gearbox, but
these transmission jacks is not lower and lifts all vehicle model gearboxes. it only used for 79
model Land cruiser vehicle gearbox. even if these transmission jack is used for 79 model vehicle
gearbox but not lower the gearbox until it sit on the ground.

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2.5. Measure I have take in order to overcome these challenge

I asked the rule and regulation of the company and I just try to understand and implement
effectively. I discussed with my supervisor about lack of safety material and he told me there is
no any budget that the company proposed for this material for intern students and I just bought to
my selves’ safety material like gloves, safety glass and safety shoes. I use locally made tools and
solve by using combined materials and for the main challenge of the company regarding to
gearbox hoist I design mechanically operating gearbox hoist which is used to lower and lift all
models of vehicle gearbox.

2.6. Overall Internship Benefits

In internship program or university industry linkage program I developed knowledge. Generally,
when I was in MOENCO (motor and engineering company of Ethiopia) I observed some
application of vehicle production factory and personal communication skill would be improved
peacefully with staff members and other work partners. Some of benefits I gained during my
internship periods are discussed as follow:

2.6.1. In terms of improving my practical skill

Working with experienced technicians gives me many skills about automotive maintenance,
repair and use of machines. Since I am mechanical student I ask different questions that are not
clear for me depending what I learn and the technicians answer my question briefly and I gain
more knowledge than I know by only theory.

2.6.2. In terms of updating my theoretical knowledge

In addition to the practical skill this program helps me to strengthen my theoretical knowledge.
The practice depends first on theory, it is easy to work for the one having good theoretical base.
Theoretical knowledge is dependable on principles, logic and calculations. Upgrading theoretical
knowledge of courses like IC engine, machine elements, motor vehicle engineering, instrument
and measurements, heat transfer, and others.

2.6.3. In terms of improving team skill

Teams need strong team players to perform well. Teams need people who speak up and express
their thoughts and ideas clearly, directly, honestly, and with respect for others and for the work
of the team. That's what it means to communicate constructively. Such a team member does not
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shy away from making a point but makes it in the best way possible in a positive, confident, and
respectful manner. The most important point in team playing skill is just reaching an agreement
from different points of view on the work to be done. At the time of discussions I gain the
different qualities of team playing skill.

2.6.4. In terms of improving leadership skill

Leadership is the process of influencing individuals or groups to accomplish an organizational
goal or mission. It is one of the most important factors for the achievement of goal. Also it is one
of the functions of management like planning; organizing, staffing and controlling Leaders are
responsible for getting the job done. So being a technical profession student, this was the most
challenging aspect for me. But finally I able to realize that leadership was a process that is not a
one time fire and forget in a progress. To be an effective leader one must be frequently exercise
good leadership skills. I do not need to be perfect but should always do my best to apply
complete leadership principles.

2.6.5. In terms of understanding about work ethics issues, industrial psychology and
related issues
Since each individual has different back ground he/she perceives things differently from others
Nevertheless, the presence of some ethical values shared by all workers. One of the ethical
values finds everywhere in professional career is punctuality. MOENCO has good work ethics in
time management. In general these work ethics are helping me to process proper behavior so as
to develop proper relation with other workers and help me to create good industrial environment.

Generally from my internship I improving the work ethics issue, the basic work ethics issues
used in the work place that we obligate to know them are as follows:

 Punctuality
 Honesty
 Reliability
 Responsibility
 Motivation
 Tolerance
 Good arrangement with others

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2.6.6. In terms of entrepreneurship skill

Before internship my understanding about Entrepreneurship was little I only seek a job from the
government and different company as monthly employer because I have no confidence in my
knowledge and I didn’t know my capacity, so this internship help me in many ways. Like Work
experiences - when during university level both paid and unpaid, help me to acquire jobs at
higher wages after graduate. Also, students who participate in occupational education and special
education in integrated settings are more likely to be competitively employed than students who
have not participated in such activities

2.6.7. In terms of improving interpersonal communication skill

The purpose of communication is to get message across the others clearly and unambiguously.
Inability to communicate makes it nearly impossible to compete effectively in the workplace and
stands in the way of career progression. From this point of view without improving our
communication skill there is no success on our job. Since services and technician work is a team
work by its nature you will face different individuals with different professions, personalities
come up together, communicate with each other to solve different problems and run the whole
work. I would like to say that I have got good lesson regarding to communication skill while my
stay in the company for the internship program.

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CHAPTER THREE
DESIGN OF MECANICALLY OPERATING GEARBOX HOIST
3.1. Problem statement and Justification
3.1.1. Problem statement
In this company there is no hoisting machine which is used for lowering and lifting gearbox of
all vehicle models while removing and remounting gearbox from vehicles. Actually the company
has a transmission jack that used for lowering and lifting gearbox, but these transmission jacks is
not lower and lifts all vehicle model gearboxes. it only used for 79 model Land cruiser vehicle
gearbox. even if these transmission jack is used for 79 model vehicle gearbox but not lower the
gearbox until it sit on the ground. after lowering some distance down, it hold on the gearbox
because of it is not capable to sit the gearbox on the ground this may cause for failure of the jack
since the gearbox is heavy in weight, so the jack is not allowed to hold the gearbox for long time.
to taking the gearbox from the transmission jack and sit the gearbox on the ground it need
manpower. The rest of all vehicle models gearbox is used manpower that needs up to 8
mechanics for lowering and lifting gearbox while removing and remounting from vehicles.
These all time spent by mechanics on gearbox removing and remounting is result for decreasing
of productivity rate and also it is risky for mechanics safety.

Figure 24: Gearbox removing

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3.1.2. Justification
In order to solve all problem in MOENCO regarding to lowering and lifting of all gearbox type I
have come up with a good idea which will solve all difficulties. I design mechanically operating
hoist which is used for all models of vehicle gearbox that is easy to work, safety to use, save
energy and time spent before which is result in increasing of productivity rate, reduce manpower
only operated by one mechanic and also lower the gearbox up to the ground or until sit on its
stand.
3.2. Objective of the project
3.2.1. General Objective
To design mechanically operating gearbox hoist
3.2.2. Specific Objective
To design basic components of the hoist
To reduce man power
To enhance productivity rate
To select the suitable material for the manufacturing
To analysis the cost required for design

3.3. Scope of Study

The design will focus only on design of gearbox hoisting machine that is used to lower and lift
gearbox while removing and remounting it from a vehicles in Adama MOENCO Company. This
project is passed many steps. those are:-
 to search the problem,
 design each components using the appropriate formula ,
 show the machine with CATIA software and
 finally I manufactured the prototype of my machine

3.4. Conceptual Design

Before choosing the right/proper outline for my machine, I have tried three different conceptual
designs. finally I see each one by one and select the best based on the following criteria:
 Cost
 Manufacturability
 Maintainability

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3.5. Working Principle

The hoist has six main mechanical parts. Those are the two left and right pillar, the upper beam
which the pulley is attached on, the bed which consists of thin flat plate and balls welded on
movable bars, shaft which is the rope drum is attached on, the worm gear, worm, bearing, handle
and the caster beam which is the wheel is attached on. to move up and down the bed we use the
handle which is connected with the worm and this worm is translate handle direction of motion
to shaft direction of motion through the worm gear which is connected to the shaft so, the
rotation of the handle rotate the shaft. When the shaft is rotated, the rope which is attached with
the bed is winded on the drum(the bed is move up) or released from the drum(the bed is move
down) which is attached on the shaft and this winding or releasing of the rope is depends on the
rotation direction of the handle. When we rotate the handle in clock wise direction the bed is
move up and when we rotate the handle in counter clock wise direction the bed is move down.
So, for lowering or lifting of the gearbox the only thing we done is sitting the gearbox on the bed
and rotate the handle to the direction we want.

Figure 25: Mechanically operating gearbox hoist

3.6. Limitation
Since my machine is mechanically operating it use manpower and also moving of the bed up and
down is need a time, so I would like to comment to design a hoist which is operated by
pneumatic, hydraulic or electrical power and also reduce moving time of the bed up and down.

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3.7. Methodology
Design and fabrication procedures for my project are as follows
 material selection  design analysis of main component
 Modelling using CATIA V5  cost analysis
 fabricating process of prototype

3.7.1. Material selecting

Selection of suitable material must to be considered in account. The suitable of material with the
process of machined as well as the compatibility of the material with the environment. The
selection of proper material for engineering the best material is one which save design objective
let the maximum cost. Different manufacturing factor have been consider selecting material is
the first target for designing or manufacturing one machine. Selecting material must consider the
requirement or the material properties, sufficient strength and easily workable. The most
economical material that satisfies both processes and mechanical requirements should be
considered the material will give that:
 Safety during working  Low cost over the working life.

 Machine ability  Availability of the material

 Suitability of material for the working consideration service

 The cost of the material and easily fabrication or machine

The material properties are very important in the selection of the material. Some important
mechanical properties which are considered in material selection are: -

 Strength.  Hardness i.e. wears resistance

 Roughness i.e. fracture resistance  Corrosion resistance

3.7.2. Design Analysis of Main Components

i. Design of Bed Cantilever Beam
The bed is seat for gearbox that moves up and down inside of the pillars. The bed of the hoist
totally consists of thin plates, balls and the two left and right cantilever beams which is the plate
is welded on it. The balls are inserted in between the plates and enable the upper plate to mobile
on it while the lower plate is welded on the cantilever beam of the bed. this beam is subjected to
bending moment and shear force due to the load of the gearbox.

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Figure 26:- 3D CATIA Design of Bed Cantilever Beam

Material selection
I select “mild steel, specification of Fe 410 “ for this beam design due to the following reason:-
 It provides high surface hardness and a soft core to parts
 It is used to prevent crashing in sever bends.
 It has excellent weld ability and produces a uniform and harder case and it
is considered as the best steel for carburized parts.
 And also has a good balance of toughness, strength and ductility.
Its mechanical property:-
 Ultimate tensile strength( ) = 410Mpa
 Yield strength ( ) = 250Mpa
 Modulus of elasticity (E) = 200Gpa

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Table 1: Indian standard

tandard designation of steel (5 page 27)
Specification
 Rectangular hole cross section
 Length = 500mm
 The weight carried(on(on one beam) =Gearbox weight(p)=150kg/2
)=150kg/2 = 75kg
W= p * g = 75*9.81 = 735.75N
Weight of gearbox is distributed on the cantilever beam of 300mm length
So, W = 735.75/0.3 = 2452.5N/m

Calculation of bending moment and shear force

Step1: To calculate the external support force

∑ = 0; RA-2452.5(0.3) = 0
RA=735.75N
∑ =0: Mo – 2452.5(0.3)(0.25) = 0
Mo= 183.94Nm

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Step2: Bending moment and shear force to get maximum moment

To get the maximum moment section the beam in to three parts and calculates the bending
moment and shear force in each section.

Section 1-1 [0≤X≤0.1m]

ℎ
1@ = 0 =0
1 − 735.75 + 183.94 = 0 − 1 + 735.75 = 0
1 = 735.75 − 183.94 = .
ℎ ∶ =0, =− .
= 0.1 , =− .

Section 2-2 [0.1≤x≤0.4m]

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ℎ
∑ =0 ∑ =0
. ( . )( . )
2 − 735.75 + 183.94 + = 0 , − 2 + 735.75 − 2452.5( − 0.1) = 0
2 = 735.75 − 183.94 − 1226.25( − 0.2 + 0.01) , 2 = 735.75 − 2452.5( − 0.1)
2 = −1226.25 + 981 − 196.2025 2 = −2452.5 + 981
ℎ ∶ = 0.1 , =− . where: x = 0.1m , V2= 735.75N
= 0.4 , =− . x =0.4m , V2= 0

Section 3-3 [0.4m≤x≤0.5m]

ℎ
=0 =0
3 − 735.75 + 183.94 + 2452.5(0.3)( − 0.25) = 0 , − 3 + 735.75 − 2452.5(0.3) = 0
3 = 735.75 + 183.94 − 735.75 − 183.9375 , 3 = 735.75 − 735.75
3 = −0.0025 =
ℎ ∶ = 0.4 , =− . where: x = 0.4m , V3 =0
= 0.4 , =− . x = 0.5m , V3= 0

 From the above calculation I get the bending moment and the Shear force in each section
of the beam the results are:-
ℎ
ℎ = , 1 = −183.94 ℎ = , 1 = 735.75
= 0.1 , 1 = −110.365 = 0.1 , 2 = 735.75
= 0.1 , 2 = −110.365 X = 0.4m , V3 = 0
= 0.4 , 2 = −0.0025 X = 0.5 , V4 =0
x = 0.4m , M3 = -0.0025Nm
x = 0.5m , M3 = -0.0025Nm

 The maximum bending moment is 183.94Nm=183940Nmm

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 The Shear Force and Bending Moment diagram of the beam is

Shear Force and Bending Moment Diagram of cantilever beam

Failure check
Check for failurity of beam due to induced bending stress in the beam.

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ℎ
: ℎ = 100 = 60
ℎ ∶
= −2 = ℎ−2
= 60 − 2 × 6 = 48 = 100 − 2 × 6 = 88 , = 0.5ℎ = 50
1
= [( ℎ − )]
12
= [(60× 100 ) – (48×88 )] =2274112mm4

From bending formula:

× ∗
= = .
= .
From standard table Fe410 steel is affordable and which have properties of:-
 = 250 >> = 4.05 ……… ℎ
The design analysis for the rest of cantilever beam is the same since equal load is distributed on
them.

ii. Design of beam

It is the upper cross bar of the hoist which is the pulley is attached on and join the two pillar.
This beam is a structural member that is subjected to transverse loads and negligible axial loads.
The transverse load causes internal shear force and bending moment on the beam.

Figure 27: 3D CATIA Design of beam

Material selection
I select “mild steel, specification of Fe 410 “ for this beam design due to the following reason:-
 It provides high surface hardness and a soft core to parts
 It is used to improve drilling machining, threading and punching
processes.
 It is used to prevent crashing in sever bends.
 It has excellent weld ability and produces a uniform and harder case and it
is considered as the best steel for carburized parts.
 And also has a good balance of toughness, strength and ductility.

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Its mechanical property:-
 Ultimate tensile strength( ) = 410Mpa
 Yield strength ( ) = 250Mpa
 Modulus of elasticity (E) = 200Gpa

Specification
 Rectangular hole cross section
 Length = 800mm
 The weight carried = weight of gearbox(150kg) + weight of bed(5kg) + weight of beam,
rope and pulley(2kg) = 157kg
Total load = w*g= 1540.17N

Calculation of bending moment and shear force

Step1: To calculate the external support force

∑ =0
1 + 2 = 1540.17
∑ = 0 , 2 × 800 − 1540.17 × 400 = 0, 2= = .
1= 2 ℎ 1 = 2 = 770.085

Step2: Bending moment and shear force to get maximum moment

To get the maximum moment section the beam in to two parts and calculates the bending
moment and shear force in each section.

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Section 1-1 [0≤X≤0.4m]

ℎ
∑ =0 ∑ =0
1 − 770.085 = 0 − 1 + 770.085 = 0
1 = 770.085 = .
ℎ ∶ = 0, =
= 0.4 , = .

Section 2-2 [0.4≤x≤0.8m]

ℎ
∑ =0 ∑ =0
2 − 770.085 + 1540.17( − 0.4) = 0 − 2 + 770.085 − 1540.17 = 0
2 = −770.085 + 616.068 =− .
ℎ ∶ = 0.4 , = .
= 0.8, =

 From the above calculation I get the bending moment and the Shear force in each section
of the shaft the results are:-
ℎ
ℎ = , 1=0 ℎ = , 1 = 770.085
= 0.4 , 1 = 308.034 = 0.8 , 2 = −770.085
= 0.4 , 2 = 308.034
= 0.8 , 2= 0

 The maximum bending moment is 308.034Nm=308034Nmm

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 The Shear Force and Bending Moment diagram of the beam is

Shear Force and Bending Moment Diagram of beam

Failure check
Check for failurity of the beam due to induced bending stress in the beam.

ℎ : ℎ = 100 = 60
ℎ ∶ = −2 = ℎ−2
= 60 − 2 × 6 = 48 = 100 − 2 × 6 = 88 , = 0.5ℎ = 50

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1
=[( ℎ − )]
12
= [(60× 100 ) – (48×88 )] =2274112mm4

From bending formula:

× ∗
= =
.
= .
From standard table Fe410 steel is affordable and which have properties of:-
 = 250 >> = 6.78 ……… ℎ

iii. Design of caster beam

Caster beam is a structural member that is subjected to transverse loads and negligible axial
loads. There is two caster beams that is the left and right pillars are welded on it. The transverse
load causes internal shear force and bending moment in the caster beam. The wheels that
enabling the hoist to move place to place are attached on this beam.

Figure 28: 3D CATIA Design of Caster beam

Material selection
I select “mild steel, specification of Fe 410 “ for this beam design due to the following reason:-
 It provides high surface hardness and a soft core to parts
 It is used to improve drilling machining, threading and punching
processes.
 It is used to prevent crashing in sever bends.
 It has excellent weld ability and produces a uniform and harder case and it
is considered as the best steel for carburized parts.
 And also has a good balance of toughness, strength and ductility.

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Its mechanical property:-
 Ultimate tensile strength( ) = 410Mpa
 Yield strength ( ) = 250Mpa
 Modulus of elasticity (E) = 200Gpa

Specification
 Rectangular hole cross section
 Length = 1200mm
 The weight carried = weight of gearbox(150kg) + weight of bed(5kg) + weight of beam,
rope and pulley(2kg) + weight of pillar and beam(3kg) = 160kg
Total load on the hoist = w*g = 1569.6N
Since there is two caster beam, the total load is divided into two W=1569.6/2=784.8N

Calculation of bending moment and shear force

Step1: To calculate the external support force

∑ =0
1 + 2 = 784.8
∑ = 0 , 2 × 1200 − 784.8 × 400 = 0, 2= = 261.6
1 = 784.8 − 261.6 = 523.2

Step2: Bending moment and shear force to get maximum moment

To get the maximum moment section the beam in to two parts and calculates the bending
moment and shear force in each section.

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Section 1-1 [0≤X≤0.4m]

ℎ
∑ =0 ∑ =0
1 − 523.2 = 0 − 1 + 523.2 = 0
1= 1 = 523.2
ℎ ∶ = 0, 1=0
= 0.4 , 1 = 209.28

Section 2-2 [0.4≤x≤1.2m]

ℎ
∑ =0 ∑ =0
2 − 523.2 + 784.8( − 0.4) = 0 − 2 + 523.2 − 784.8 = 0
2 = −261.6 + 313.92 2 = −261.6
ℎ ∶ = 0.4 , 2 = 209.28
= 1.2, 2=0

 From the above calculation I get the bending moment and the Shear force in each section
of the shaft the results are:-
ℎ
ℎ = , 1=0 ℎ = , 1 = 523.2
= 0.4 , 1 = 209.28 = 1.2 , 2 = −261.6
= 0.4 , 2 = 209.28
= 1.2 , 2= 0

 The maximum bending moment is 209.28Nm=209280Nmm

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 The Shear Force and Bending Moment diagram of the beam is

Shear Force and Bending Moment Diagram of caster beam

Failure check
Check for failurity of the beam due to induced bending stress in the beam.

ℎ : ℎ = 100 = 60
ℎ ∶ = −2 = ℎ−2
= 60 − 2 × 6 = 48 = 100 − 2 × 6 = 88 , = 0.5ℎ = 50

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1
[( ℎ −
= )]
12
= [(60× 100 ) – (48×88 )] =2274112mm4
From bending formula:
× ∗
= =
.
= .

From standard table Fe410 steel is affordable and which have properties of:-
 = 250 >> = 6.92 ……… ℎ
The designing process of the left side caster beam is the same as that of the right side caster
beam.

iv. Design of Rope

The rope drives are widely used where a large amount of weight is to be transmitted. In my
design I use a rope for lowering and lifting of the bed. This rope is first attached to the bed and
by passing on the pulley it is fixed on the drum of the rope which is welded on the shaft. so,
when the bed is moved up the rope is winded on the drum and when the bed is lowered the rope
is released from the drum. The rope drives use the following two types of ropes :
1. Fibre ropes, and 2. Wire ropes.
Material selection
I select “a steel wire rope, due to the following reason:-
1. These are lighter in weight, 2. These offer silent operation,
3. These can withstand shock loads, 4. These are more reliable,
5. These are more durable, 6. They do not fail suddenly,
7. The efficiency is high, and 8. The cost is low.
Specification:
 total weight on the rope (p) = weight of gearbox(150kg) + weight of bed(5kg)= 155kg
W= p*g = 155x9.81 = 1520.55N

Procedure for Designing a Wire Rope

1 .First of all, select a suitable type of rope from standard rope design tables(SRDT) for the given
application.
2. Find the design load by assuming a factor of safety 2 to 2.5 times the factor of safety given
in SRDT.
3. Find the diameter of wire rope (d) by equating the tensile strength of the rope selected to the
design load.
4. Find the diameter of the wire (dw) and area of the rope (A) from SRDT.
5. Find the various stresses (or loads) in the rope.
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6. Find the effective stresses (or lloads)
oads) during normal working and during starting.
7. Now find the actual factor of safety and compare with the factor of safety given SRDT. If the
actual factor of safety is within permissible limits, then the design is safe.

The following procedure may be adopted in selecting a wire rope for my hoist.
1. From standard rope design Table, I find that the wire ropes for hoisting purposes are of two
types, i.e.. 6 × 7 and 6 × 19. I take a rope of type 6 × 19.
2. From Table, I find that the factor of safety for hoist is 3.5.. Since the design load is calculated
by taking a factor of safety 2 to 2.5 times the factor of safety given in Table , therefore I take the
factor of safety as 7.
∴ Design load for the wire rope = 7 × 1520.55 = 10643.85N
3. From Table, I find that the tensile strength of 6 × 19 rope made of wire with tensile
strength of 1100MPa is 385 d2 (in newton), where d is the diameter of rope in mm. Equating this
tensile strength
ngth to the design load, I get
385 d2 = 10643.85
∴ d 2 = 10643.85 / 385 = 27.65
d = 5.26 say 6mm(nominal
(nominal diameter)
diame
4. From Table, I find that for a 6 × 19 rope,

Table 2: Standard Wire rope table (5 page 747)

Diameter of wire, dw = 0.063 d = 0.063 × 6 = 0.378mm
and area of rope, A = 0.38 d2 = 0.38 (6)2 = 13.68 mm2
5. Now let us find out the various loads in the rope
ro as discussed below :
(a) From Table, I find that weight of the rope,
w = 0.0383 d 2 = 0.0383 (6)2= 1.38N/m = 1.38 × 3 = 4.14N ...( length = 3 m)
(b) From Table, I find that diameter of the sheave (D)
( ) may be taken as 60 to 100
times the diameter of rope ( d ). I choose

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D = 30d = 30 × 6 = 180 mm
∴ Bending stress,
× ∗ .
= = = 176.4N/mm2 ...(Taking Er = 84 × 103 N/mm2

and the equivalent bending load on the rope, for steel wire rope)
Wb= σb × A = 176.4× 13.68 = 2413.152 N
(d) the impact load during starting (when there is no slackness in the rope),
Wst = 2 (W + w) = 2(1520.55 + 4.14) = 3049.38 N
6. the effective load on the rope during normal working (i.e. during uniform
lifting or lowering of the load)
= W + w + Wb = 1520.55 + 4.14 + 2413.152 = 3937.84 N
∴ Actual factor of safety during normal working
.
= = 2.7
.

Effective load on the rope during starting

= Wst + Wb = 3049.38 + 2413.152 = 5462.5 N
∴ Actual factor of safety during starting
.
= 1.95
.

Since the actual factor of safety as calculated above are safe, therefore a wire rope of diameter
6mm and 6 × 19 type is satisfactory.

v. Design of Worm gearing

The worm gearing is consists of worm and a worm wheel or gear. The worm (which is the
driving member) is usually of a cylindrical form having threads of the same shape as that of an
involute rack. The threads of the worm may be left handed or right handed and single or multiple
threads. The worm wheel or gear (which is the driven member) is similar to a helical gear with a
face curved to conform to the shape of the worm. The worm is generally made of steel while the
worm gear is made of bronze or cast iron for light service. I select steel for worm and phosphor
bronze for the worm gear.

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In designing a worm and worm
gear, the quantities
quan like the
power, velocity ratio and the
centre distance between the
shafts are usually given and the
quantities such as lead angle,
lead and number of threads on
the worm are
ar to be determined.
In order to determine the
satisfactory combination of lead
angle, lead and centre distance.

Specification
 20° involute worm and gear to transmit 20W
2
 V.R = 4
 The distance between the shafts is 100 mm

The worm and gear is designed as discussed below:

1. Design of worm
Let lN = Normal lead, and
λ = Lead angle.
the value of x / lN will be minimum corresponding to
cot3 λ = V.R.. = 4 or cot λ = 1.59
∴ λ = 32.2°
We know that

.
= ( + )
= ( + ) = 6.6
. .
∴ lN = 100/ 6.6 = 15.15 mm
and axial lead, l = lN
N / cos λ = 15.15 / cos 32.2° = 17.9 mm

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From Table , I find that for a velocity ratio of 4, the number of starts or threads on the
worm, n = Tw = 6
∴ Axial pitch of the threads on the worm,
pa= l / 4 = 17.9 / 4 = 4.47 mm
∴ m = pa/ π = 4.47 / π = 1.42 mm
Let us take the standard value of module, m = 2 mm
∴ Axial pitch of the threads on the worm,
pa= π m = 3.13x2 = 6.28 mm
Axial lead of the threads on the worm,
l = pa x n = 6.28 × 6 = 37.68 mm
and normal lead of the threads on the worm,
lN= l cos λ = 37.68 cos 32.2° = 31.88 mm
We know that the centre distance,

. .
= ( + )= ( + ) = 33.52mm
. .
Let DW = Pitch circle diameter of the worm.
.
tan λ = ==> Dw = = .
= 19mm
Since the velocity ratio is 4 and the worm has sextuple threads (i.e. n = TW = 6), therefore
number of teeth on the worm gear,
TG= 4 × 6 = 24
From Table, I find that the face length of the worm or the length of threaded portion is
LW= pc(4.5 + 0.02 TW)= 6.28 (4.5 + 0.02 × 6) = 29mm ...( pc = pa)
This length should be increased by 25 to 30 mm for the feed marks produced by the vibrating
grinding wheel as it leaves the thread root. Therefore let us take
LW= 50 mm
We know that depth of tooth,
h = 0.623 pc= 0.623 × 6.28 = 3.9 mm
...(From Table )
and addendum, a = 0.286 pc= 0.286 × 6.28 = 1.79mm
∴ Outside diameter of worm,
DOW = DW + 2a = 19 + 2 × 1.79 = 22.6 mm

2. Design of worm gear

We know that pitch circle diameter of the worm gear,
DG = m x TG = 2 × 24 = 48 mm = 0.048 m
From Table, I find that outside diameter of worm gear,
DOG = DG + 0.8903 pc = 48 + 0.8903 × 6.28 = 53.59 mm
Throat diameter,
DT = DG + 0.572 pc = 48 + 0.572 × 6.28 = 51.59 mm

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and face width, b = 2.15 pc+ 5 mm = 2.15 × 6.28 + 5 = 18.5 mm
now check the designed worm gearing from the standpoint of tangential load, dynamic
load and static load or endurance strength.

(a) Check for the tangential load

Let NG = Speed of the worm gear in r.p.m.
velocity ratio of the drive,
V.R = ==> NG = = = 20 rpm
.
∴ Torque transmitted,
T= = = 9.55Nm
and tangential load acting on the gear,
.
WT = = = 397.9N
.
pitch line or peripheral velocity of the worm gear,
.
v= = = 0.05m/s
∴ Velocity factor,
Cv = = .
= 0.99
and tooth form factor for 20° involute teeth,
. .
y = 0.154 – = 0.154 – = 0.116

Since the worm gear is generally made of phosphor bronze, therefore taking the allowable static
stress for phosphor bronze, σo = 84 MPa or N/mm2.
the designed tangential load,
WT = (σo x Cv) b. π m . y
WT= (84 × 0.99) 18.5 × π × 2 × 0.116= 1120.7 N
Since this is more than the tangential load acting on the gear (i.e. 397.9 N), therefore the design
is safe from the standpoint of tangential load.

(b) Check for dynamic load

the dynamic load,
WD= WT / Cv = 1120.7 / 0.99 = 1132.2 N
Since this is more than WT = 397.9 N, therefore the design is safe from the standpoint of
dynamic load.

(c) Check for static load or endurance strength

the flexural endurance limit for phosphor bronze is σe = 168 MPa or N/mm2
∴ Static load or endurance strength,
WS= σe. b. π m . y = 168 × 18.5 × π × 2 × 0.116 = 2264.11 N
Since this is much more than WT = 397.9 N, therefore the design is safe from the standpoint of
static load or endurance strength.

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vi. Design of worm gear shaft

Figure 29 : 3D CATIA Design of Shaft

Let dW = Diameter of worm shaft.
torque acting on the worm gear shaft,
. .
Tgear = = = 11.9 Nm
∴ Torque acting on the worm shaft,
.
Tworm = = = = 3.35Nm
. .
tangential force on the worm,
WT= Axial force on the worm gear
.
WT = = .
= 352.6N
Axial force on the worm,
WA = Tangential force on the worm gear
.
WA = = .
= 495.8 N
and radial or separating force on the worm
WR = Radial or separating force on the worm gear
= WA . tan φ = 495.8 × tan 20° = 180.45 N
so, the total force on the worm transmitted to the handle of the hoist = 1028.85N
from 1520.5N total load need to operate the hoist 1028.85N force is covered by the worm
gearing mechanism, the rest 491.7N force is filled by man power.
the distance between the bearings of the worm shaft (x1) equal to the diameter of the
worm gear (DG), i.e.x1 = 100mm
∴ Bending moment due to the radial force (WR ) in the vertical plane
.
= = = 4511.4 Nmm
and bending moment due to axial force (WA) in the vertical plane
.
= = = 2355.05Nmm

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∴ Total bending moment in the vertical plane,
M1 = 4511.4 + 2355.05 = 6866.45 N-mm
bending moment due to tangential force (WT) in the horizontal plane,
.
M2 = = = 4231.2 Nmm
∴ Resultant bending moment on the worm gear shaft,
Mwgs = √ 1 + 2 = √6866.45 + 4241.2
Mwgs = 8065.43 N-mm
equivalent twisting moment on the worm gear shaft,
Tew = + = √11900 + 8065.43 = 14375.7 N-mm
equivalent twisting moment (Tew),
14375.7 = ( ) = 50( ) ...(Taking τ = 50 MPa or N/mm2)
dG3 = 1465
dG = 11.36 = 12 mm
check the maximum shear stress induced.
the actual shear stress,
.
τ= = = 42.39N/mm2
and direct compressive stress on the shaft due to the axial force,
.
σc = / ( )
= / ( )
= 4.38 N/mm2
∴ Maximum shear stress,
τmax = σ + 4( ) = 4.38 + 4(42.39)
τmax = 42.45N/mm2
Since the maximum shear stress induced is less than 50 MPa (assumed), therefore the design of
worm gear shaft is satisfactory.

vii. Design of Pillar

The pillar is the support that carries the all load of the machine. In my machine I use two support
pillars. The two pillars are carries the load of the gearbox, the load of the beam and the load of
the bed. The pillar have channel like cross section which is the bed is move up and down inside
of the channel. This pillar may be designed to normal stress and buckling.

Figure 30: 3D CATIA Design of pillar

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Material selection
I select “mild steel, specification of Fe 410 “for this pillar design due to the following reason:-
 It provides high surface hardness and a soft core to parts
 It is used to improve drilling machining, threading and punching
processes.
 It is used to prevent crashing in sever bends.
 It has excellent weld ability and produces a uniform and harder case and it
is considered as the best steel for carburized parts.
 And also has a good balance of toughness, strength and ductility.

Its mechanical property:-

 Ultimate tensile strength( ) = 410Mpa
 Yield strength ( ) = 250Mpa
 Modulus of elasticity (E) = 200Gpa

Specification
 channel cross section
 Length = 1600mm
 The load carried =gearbox load(150kg) + bed load(5kg) + beam and rope load(2kg)
= (157 ) …… = 9.81
The Total load applied on the beam is,
= 9.81(157) , = 1540.17
.
 Load on each pillar, = = .
ℎ, = 1600 ℎ , =6
ℎ : = 100 = 60
= 12 , h = 18.58mm and h1 = 41.42mm

, =[ +( − ) ]
A = [100x6+ (60-6)12] = 1248
.
Normal stress on the pillar is, = = = 0.62Mpa
Designed stress; x n = 0.62Mpa x 4= 2.47Mpa
Therefore I select from Indian standard steel table
 Ultimate tensile strength( ) = 410Mpa
 Yield strength ( ) = 250Mpa
 Modulus of elasticity (E) = 200Gpa

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Design to buckling

Table 3: Actual and equivalent length of pillar (5 page 604)

Effective length for two sides of fixed ends column are get the formula from table
= 0.5 = 0.5 × 1600 = 800
 Moment of inertia due to xx-axis

Table 4: Standard Table

Tab of Channel section (5 page 134)
1
= [( ℎ − (ℎ − ) ) + ℎ1 ]
3
= [(100 18.58 297526.96mm4
58 − 88(18.58 − 6) ) + 6 41.42 ] =297526.96mm
 .
Radius of gyration; = = = 238.4mm
 Slenderness ratio, = = 3.36
.
Hence critical load and critical stress of the pillar as determined based on Rankin’s formula to
buckling, since its slenderness ratio are below 80.
Using EULER’S formula to find critical stress and load as follows:-
follows:
× × × .
 Critical load due to X--axis; = = =916.72KN
( )
× ×
 Critical stress, = = = 174666.9Mpa
( ⁄ ) ( . )
 >> … ℎ ℎ
 ( >> … . ℎ ℎ
Therefore those pillars are safe to critical
criti stress and loads because my load and stress are less
than the critical then in these two reasons the material is safe.

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3.7.3. Fabricating process of prototype

The processes used in fabrication of my project prototype are Cutting, Welding, Drilling and
Fastening: first start by outlaying everything and deciding on a design. Before welding all the
pieces together, I first sketch my hoist to make it compatible by free hand drawing. Then after
finishing the sketch, I begin my manufacturing process starting from cutting pieces of square
hollow tube steel at designed dimension of height, length and width of the frame. After cutting
the pieces I proceed to welding process of the frame. The bed which consists of balls and the two
upper and lower plates are joined together as enabling the upper plate to mobile on the lower
plate by mechanism of inserting those balls in between the plates. Then the bed is welded on the
cantilever beam frame. The shaft, the rope, the pulley and the handle is also attached on their
place as it makes the machine functional. Totally the manufacturing process like welding,
drilling, cutting and fastening is used in the place I wanted and finally I finished my work by
making my hoist workable.

Figure31: fabrication process of my project prototype

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3.7.4. Cost analysis

Cost analysis is an art or finding the cost, which is likely to be incurred on the manufacture of an
article, after it actually manufactured. Thus, it is the calculation of a probable cost of an article
after the manufacturing ends. It also includes predetermination of the quantity and quality of
materials, labour required, etc. estimating requires highly technical knowledge about
manufacturing methods and operation times etc.
No. Part of the hoist Bill of Quantity Cost of element
materials Material Labor Total cost
cost(unit cost (in birr)
price)
1. Pillar Cast iron 2 300.00 50.00 650.00

2. Beam Cast iron 1 150.00 20.00 170.00

3. Bed Cast iron 1 1200.00 300.00 1500.00

4. Caster beam Stainless steel 2 600.00 80.00 680.00

5. shaft Cast iron 1 300.00 100.00 400.00

6. Worm and worm gear Phosphor 1 750.00 750.00
bronze & steel
7. Pulley Stainless steel 1 200.00 200.00

8. Bearing copper 1 250.00 250.00

9. Rope steel 2m 300.00 300.00

10. Rope drum Cast iron 1 150.00 150.00

11. Handle Cast iron 1 200.00 100.00 300.00
12. other 1000.00
Total 6350 birr
Table 4: cost analysis table

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CHAPTER FOUR
GENERAL CONCLUSION AND RECOMMENDATION
4.1. Conclusions
Generally, both the internship and the project were completed with great conditions. In the last
four months I had worked in the company, MOENCO ADAMA branch, I have gained many
skills. It gave me the highlight of my future as I am a mechanical engineer. It also gave me the
chance to revise what I have learned for the past four years directly or indirectly. It was a big
step in improving my communication, team playing and leadership skills, improving practical
skills, upgrading of theoretical knowledge, understanding of work ethics and entrepreneurship
skills, industrial problem solving capabilities. It was the best way to see my theoretical
knowledge and experience it in the real life. In my stay in this company I obeyed the rules and
regulation of the company, for example, coming early in the morning and obeying companies
work disciplines. This helps me to be a good and disciplined worker for future work experience
in any environment. Generally, my stay in this company meets the main objective of the
internship program which helps a student who is well armed in theoretical and practical
knowledge.
Finally I conclude that this project can achieve the main objective of my design. the project is
successfully carried out on aspects of design analysis of various components, time consumption
and requirements of human effort. The designed gearbox hoist is very efficient and easy to
operate. which is expected to solve problem in the company and maintain mechanics health well.
So, one person is capable to operate the hoist which holds the gearbox of having max. weight of
1471.5N. In the analysis part, it is concluded that most of the dimensions and parameters are
filled, strength and other criteria’s checked. In addition, a clear and legible assembly drawing
with 3D views, and detail drawings are included. All materials used are locally available and at a
low cost of 6350 birr making the hoist economically viable. But I am not use the proper materials
as I design due to absence of material so, I fabricate the prototype of the hoist.

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4.2. Recommendation
I recommend the university to ask and tell the company’s willing or accepting our internship
paper when entering the company. Because it is hard for a student to be accepted by some
companies, so the university should create a new system to join the company with the student
easily. I also recommend the university to regularly control the student’s status. In my point of
view, it is useful for a student to study more practical knowledge than theoretical knowledge.
And I saw in this internship program really helpful in creating a highly competent student, so I
recommend the university to prepare an internship program more than once in BSC program.

Recommendation to the company:

 Oil drain container should be used in service and repair shop for safety purpose.

 A table should be made for putting disassembled parts of an engine, transmission, differential in
unit rebuild shop.

 The company should give a sufficient lecture for each worker in order to make them familiar
with the available tools in SST (special service tools) room.

 The company should have a car pulling machine in its compound rather than wasting the time &
energy of the workers.
 The designed hoist should be put in to practice for desire work task

I recommend that anybody who is interested in this subject can be upgraded to more user
friendly by adding the features such as fully hydraulic or electrical or pneumatic, increase the
effectiveness and performance of machine. I suggest that the automotive industry like MOENCO
have to use latest and simple machine to improve and increase productivity by saving the time
and labour energy. This machine is very useful to the all branches of MOENCO, which are
service different models of vehicles. The cost of this machine is very less as compared to the
advantage we get from the hoist so, the company should have to use this hoist by manufacturing
it. It also can be used as a lifting machine for other purpose.

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Reference
1. Beer, Ferdinand, P., Mechanics of Materials, Second Edition, McGraw-Hill, Inc.: Santa Fe,
NM 1992.

2. Company’s history profile and Company’s service & repair manual.

3. Web link: http://www.toyota-gib.com

4. R.S. Khurmi, J.K. Gupta, “A Text book on Machine Design” 2002, 13th edition & fifth edition
5. Shigley’s Mechanical Engineering Design, Eighth Edition Text: by Budynas−Nisbett.

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Appendices

Part drawing
i. Bed

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ii. Rope drum

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iii. Pulley

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iv. shaft

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vi. Worm gear

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Assembly drawing

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