Vertical Lift Bridge - Project Report 3x66k

VERTICAL LIFT BRIDGE A PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF DEGREE OF

BACHELOR OF TECHNOLOGY In Mechanical Engineering SUBMITTED BY Sachin Kumar Sumit kumar Rohit Sharma Hitesh Maggo Sajan Khamish

2313647 2313648 2313656 2314788 2314789 2314791

SUBMITTED TO

Department of Mechanical Engineering Ambala College of Engineering and Applied Research, Ambala (d With)

Kurukshetra University, Kurukshetra December 2016

VERTICAL LIFT BRIDGE A PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF DEGREE OF

BACHELOR OF TECHNOLOGY In Mechanical Engineering SUBMITTED BY Sachin Kumar Sumit kumar Rohit Sharma Hitesh Maggo Sajan Khamish

2313647 2313648 2313656 2314788 2314789 2314791

UNDER THE GUIDANCE OF Prof. Amit Arya Designation ME Department ACE, Ambala SUBMITTED TO

Department of Mechanical Engineering Ambala College of Engineering and Applied Research, Ambala December 2016

CANDIDATE'S DECLARATION We,

Sachin(2313647),

Sumit(2313648),

Rohit(2313656),

Hitesh(2314788),

Sajan(2314789), Khamish(2314791) hereby declare that the work which is being presented in the project entitled, “VERTICAL LIFT BRIDGE” in partial fulfillment of requirement for the award of degree of B.Tech. (ME) and submitted in the Department of Mechanical Engineering, Ambala College of Engineering and Applied Research, Ambala, Kurukshetra University, Kurukshetra, is an authentic record of my/our own work carried by me under the supervision of Amit Arya (Designation, Mechanical Department, Ambala College of Engineering and Applied Research, Ambala).The matter presented in this project Report has not been submitted in this or any other University / Institute for the award of B.Tech Degree. Dated: (Sachin) 2313647 Dated: (Sumit) 2313648 Dated: (Rohit) 2313656 Dated: (Hitesh) 2314788 Dated: (Sajan) 2314780 Dated: (Khamish) 2314791

Department of Mechanical Engineering

Ambala College of Engineering and Applied Research, Ambala (d With) Kurukshetra University, Kurukshetra – 136119 (Established by the state legislature Act XII of 1956) (“A” Grade, NAAC Accredited)

CERTIFICATE Certified that this project report entitled “VERTICAL LIFT BRIDGE” is the bonafide work of “Sachin(2313647), Sumit(2313648), Rohit(2313656), Hitesh(2314788), Sajan(2314789), Khamish(2314791) of 7th Semester, Mechanical Engineering, Ambala College of Engineering and Applied Research, Devsthali, Ambala”, who carried out the project work under my supervision during August, 2016 - November, 2016.

(Amit Arya)

(Ashwani Verma)

Supervisor

Project Coordinator

Assistant Professor

Assistant Professor

ME Department, ACE

ME Department, ACE

The above statement is correct to the best of our knowledge.

(

)

External Examiner

(Dr. S.K Jain) Associate Professor Head of Department

ACKNOWLEDGEMENTS The Project work is an important aspect in the field of engineering, where contribution is made by many persons and organizations. The present shape of this work has come forth after contribution from different spheres. Give acknowledgement to Guide. Give acknowledgement to H.O.D I would also like to thank my parents etc who helped me in my Project. I express my sincere gratitude to Ambala College of Engineering and Applied Research, Ambala and Kurukshetra University, Kurukshetra for giving me the opportunity to work on the Project during my final year of B.Tech. At the end thanks to the Almighty for …………

(Sachin) 2313647

(Sumit) 2313648

(Rohit) 2313656

(Hitesh) 2314788

(Sajan) 2314780

(Khamish) 2314791

ABSTRACT

The bridge has a unique feature that it based on the “Vertical Lift Mechanism”, its middle (movable) part lifts to give way to the ship ing by thus maintaining waterways transport. Till now no bridge such has been built in India.

Contents Candidate’s Declaration

i

Certificate

ii

Acknowledgement

iii

Abstract

iv

Chapter 1

INTRODUCTION

1-3

1.1

Role and responsibility

2

1.2

Personal Engineering Activity

2

Chapter 2

LITERATURE SURVEY

Chapter 3

COMPONENTS & DECRIPTION

Chapter 4

EXPERIMENTAL MODEL

4-16 17-25 26

Chapter 5

CONCLUSION

27

Chapter 6

REFERENCES

28

Chapter 1

INTRODUCTION A vertical-lift bridge or lift bridge is a type of movable bridge in which a span rises vertically while remaining parallel with the deck which ensures ing of ships underneath. They cost less to build for longer moveable spans. The counterweights in a vertical lift are only required to be equal to the weight of the deck. Thus heavier materials can be used in the deck, and so this type of bridge is especially suited for heavy railroad use. It is also more energy efficient, requiring comparatively less power to lift the bridge. The project is a prototype of such a bridge and utilizes a chain drive mechanism to lift the middle span of the bridge.

The vertical lift offers several benefits over other movable bridges such as the bascule and swing-span bridge. Generally speaking they cost less to build for longer moveable spans.[1] The counterweights in a vertical lift are only required to be equal to the weight of the deck, whereas bascule bridge counterweights must weigh several times as much as the span being lifted. As a result, heavier materials can be used in the deck, and so this type of bridge is especially suited for heavy railroad use. Although most vertical-lift bridges use towers, each equipped with counterweights, some use hydraulic jacks located below the deck. An example is the 52-foot (16 m) span bridge at St Paul Avenue in Milwaukee[2] (see also table bridges). Another design used balance beams to lift the deck, with pivoting bascules located on the top of the lift towers.[3] An example of this kind was built at La Salle in Illinois, USA. The biggest disadvantage to the vertical-lift bridge (in comparison with many other designs) is the height restriction for vessels ing under it. This is a result of the deck remaining suspended above the ageway.

1.1 Role and Responsibilities My roles and responsibilities includes: 

Prepare a requirement document to reach expectations of project and to come up with functionalities which are needed to be implemented.



Documentation of expected output for various aspects with accepted margin error was also documented.



To design overall system based on workflow requirements.



Discussion with the project guide and Head of Department on ways to improve the design and to optimize performance.



Choosing suitable components and methods based on the configurations availability and requirements.



Testing and remedies.



Recommendations

As a trainee mechanical engineer, I wanted to work on a project work that would showcase my engineering knowledge. I got the opportunity to work on VERTICAL LIFT BRIDGE. This project was very important as it evaluated my skills and talents in my company.

1.2 PERSONAL ENGINEERING ACTIVITY As a mechanical engineer, before undertaking any task I checked the feasibility of the project. In this project, my role is as team . This report provides an insight into the design and fabrication of VERTICAL LIFT BRIDGE. I wanted to know more details of the project before commencing; hence, I researched the topic thoroughly by referring to journals and articles online. Additionally, I obtained more information by taking references about the topic.

Lift bridges state of the art Among mobile bridges, lift ones appear as the right answer when relatively long spans are needed. Bascule bridges or rotating ones are more limited, because of their overhanging decks. In the existing lift bridge with the longest span is “Recouvrance” Bridge in Brest, with an 87.5 meters lifting span. But most large bridges of this kind are located in New Jersey, USA where many waterways allow maritime traffic. The longest lifting span in the world belongs to Arthur Kill Bridge with 170 meters, no longer in operation. Another significant structure is the Gil Hodges Memorial Bridge , with a main span in the range of 160 meters.

Description This project is a model and a simplified version of Kattwyk Bridge and has been made under the constraints of space, time and resources available in the lab. The Bridge mechanism has been divided in three sections. The central section lifts above, while the two side parts remain intact with the ing angles. The lift mechanism used for the bridge is based on the pulley system involving three pulleys. A string is ed through the two pulleys on either side of middle section and the pulley at the centre synchronizes the motion of two pulleys and makes the motion centralized. The angles are used to restrict the motion of central section allowing only the motion in vertical direction to occur and provide the stability to the bridge structure. A chain is also used to stop the central section at any desired height depending on the height of ship assuming a real case situation thus saving the power. The mechanism used to lift the central section is due to the constraint of not using any electric motor or gears. In real case situation, the power can be given by electric motors and cables can be used. The four bridge ing angles that connect the three sections of the bridge will actually go till the bottom surface of the river.

Chapter 2 LITERATURE SURVEY METHODOLOGY When a handle attatched at the bottom is rotated the middle span is lifted by 2 ropes, 1 at each extremity. The ropes are attached to the 2 S-hooks which raise the bridge span. The ropes which go over the side pulleys wrap around the central pulley thus shortening the length of ropes and causing lifting. MATERIALS USED 

Mild Steel rods



MS plates, angles and screws



Wood



Aluminium sheet

PROCESSES REQUIRED Lathe Operations, Drilling, Welding, Grinding, cutting TECHNICAL SPECIFICATIONS The provisional specifications of the vertical-lift bridge are specified as below: 

The length of the bridge frame is 2 ft.



The height of the bridge frame is 3 ft.



The aluminium strips that form the truss are 0.5 inch in thickness and the height of the middle span is 7 inches.

Fig 1

Fig 2

The main parts and components have been discussed in the following sections. The vertical-lift bridge is divided into the following 3 broad categories: 

Bridge Span



Bridge Frame



Chain Drive Mechanism

 BRIDGE SPAN Manufacturing processes used: Cutting/sawing The bridge span includes the 1. Middle Span Function: the base of the bridge which is to be lifted. Material: wood, aluminium, mild steel Dimensions:  Wooden base length of 21in and width 8 inches.  Aluminium strips of 0.5 inch thickness  2 wooden Top chords of length 21in and thickness 1 inch.  2 MS connecting rods

Sequence of operations: 1. Obtained wood from scrap. 2. The required dimensions of the base and the top chords were obtained using a hacksaw. 3. 2 holes each on the 2 chords were drilled. 4. The strips were cut from an aluminium sheet using the shape cutting machine and they function as the webs of the truss. 5. The strips were hammered onto the base and the chords to form the struss. 6. The top chords were machined on the lathe using the turning operation to get the desired diameter and then fixed into the holes to connect the top chords. 7. Finishing was done by applying primer and finally paint was applied. 2. Side Spans Function: the extensions of the span on either side of the middle span. Material: wood, aluminium Dimensions: 2 Top chords: Length of 9.5 inches, height=1.5 inches, width=1 inch Sequence of operations: 1. Obtained wood from scrap. 2. The required dimensions of the base and the top chords were obtained using a hacksaw. 3. 2 holes each on the 2 chords were drilled. 4. The strips were cut from an aluminium sheet using the shape cutting machine and they function as the webs of the truss. 5. The strips were hammered onto the base and the chords to form the struss. 6. The top chords were machined on the lathe using the turning operation to get the desired diameter and then fixed into the holes to connect the top chords.

7. Finishing was done by applying primer and finally paint was applied.

 BRIDGE FRAME Fig 3

FIG 4

Manufacturing processes used:  Welding  Turning  Drilling

1. L-Brackets Function: form the against which the middle span of the bridge rises. Dimensions: height = 3ft ,thickness=0.25 in, width=1 in 2. ing plates Function: hold the L-brackets in vertical position together. Quantity: 12 Material: Mild steel Dimensions: 

6 plates of length=8 in and thickness=1 in



6 plates of length=2ft and thickness=1 in

3. Pulleys Middle pulley Function: causes the movement of the side pulleys which in turn cause the ropes to pull the bridge upwards. Material: wood

Quantity: 1 Dimensions: 3 in diameter, thickness of the 2 grooves=0.25 in, total width of pulley=1.75in Side pulleys Function: cause the ropes to lift the bridge by wrapping the ropes in the V-groove machined on the pulley surface. Material: wood Quantity: 2 Dimensions: 3 in diameter, width = 1 in 4. Connecting rods Function: the pulleys Material: MS Quantity: 3 Dimensions: diameter=0.5 in, length=6 in Sequence of operations: 1. MS angles and plates were obtained from the scrap. 2. The plates were welded onto the angles using arc welding.(fillet weld). 3. Holes were drilled into the frame for the 3 connecting rods as well as the MS rod fixed at the bottom of the frame over which the the sprocket gear rotates. 4. The connecting rods were machined on the lathe using the turning operation to the diameter of the hole.

5. Holes were drilled into the rods and pins were used to fix the rods in place and prevent axial movement. 6. The sprocket was welded onto the middle connecting rod.(tac welds) Sequence of operations for pulleys 1. A rectangular block of wood was obtained from the scrap. 2. The block was machined to get a cylindrical block using the wood cutting machine. 3. The wooden cylinder was divided into 3 parts. 4. Each part had a hole drilled into it using the drilling machine. 5. The V-grooves were machined onto the surface using a lathe. The pulleys were attached to the rods and the rods were fixed using washers and pins.

 CHAIN DRIVE MECHANISM Fig 5

Fig 6

Manufacturing processes used: 

Drilling



Boring



welding

1.Sprocket gear Function: cause the movement of the middle pulley. Material: MS Quantity: 2 Dimensions: 

gear at the bottom has diameter 4 in with 22 teeth



gear attached to the middle pulley has dia 4 in with 18 teeth

2.Hollow pipe/Bearing/Connecting rod Function: cause the movement of the sprocket at the bottom Material: MS Quantity AND Dimensions: 

1 bearing of dia 1.25 in



1 connecting rod of dia 0.5 in and length 8 in

3.Chain Function: goes over the sprocket gears to cause their movement. 4.Handle Function: used to rotate the sprocket gears Material: MS 5.Ropes Function: lift the bridge to the desired level Material: jute Quantity: 2 6.S-hooks Function: lift the bridge to the desired level Material: MS Quantity: 2 Dimensions: 

dia of loop=0.5 in

Sequence of operations: 1. The bushings were welded onto the sprockets. 2. For the bottom sprocket bearing was press fitted onto the pipe and the sprocket was fixed over the pipe. The pipe with the bearing was fixed over the connecting rod. 3. For the sprocket gear at the top a cylindrical blank was turned to fit into the bushing. 4. A hole of diameter 0.5 in was drilled into it. The cylindrical rod was welded onto the bushings and then onto the connecting rod for the middle pulley. 5. Ropes were nailed onto the central pulley and ed over the side pulleys. 6. The ropes were attached to the chord connecting rods through S-hooks of 0.5 inch dia. 7. The chain was put over the sprockets. 8. The handle was welded onto the pipe.

 Problems faced while working 

Wobbling occurred while machining a long rod on the lathe machine leading to a very high eccentricity.



Large depth of cut in turning led to poor surface finish of connecting rods.



Lesser bridge thickness led to chipping of wood due to hammering.

Difficulties and Remedies The difficulties faced are: 1. SETTING THE CENTRAL LIFT PART IN POSITION : To set the exact clearance for the middle section to give it smooth movement in vertical direction. 2. ALIGNING THE RODS: Problems while aligning the small parts for welding. 3. Weight lifting mechanism and stopping the central part at any desired height. 4. MACHINING PROBLEM: Filing and Machining all the parts welded was difficult. The Remedies and changes made to overcome the difficulties: 1. Brazing was used wherever it was not possible to do welding. 2. Initially the mechanism for lifting the central part involved the use of weights but it was not an efficient mechanism and it was not possible to stop the bridge at any desired height so it was decided to use pulleys and move the central pulley manually using handle. 3. Whole construction process was divided in separate sections such as movable and two side sections of bridge, pulley making, filing and machining parts separately and finally all parts were assembled. 4. We tried our best in getting the exact measurement and maintain the symmetry with patience, coordination and team spirit.

Chapter 3 COMPONENTS AND DESCRIPTION 3.1 MAIN COMPONENTS 

FRAME



PULLEY



ROPE



CHAIN DRIVE



SPROCKETS



S - HOOKS



BEARINGS



HEX NUT



BOLT



WASHER

3.2 DESCRIPTION  CHAIN DRIVE

Chain drive is a way of transmitting mechanical power from one place to another. It is often used to convey power to the wheels of a vehicle, particularly bicycles and motorcycles. It is also used in a wide variety of machines besides vehicles. Most often, the power is conveyed by a roller chain, known as the drive chain or transmission chain,[1] ing over a sprocket gear, with the teeth of the gear meshing with the holes in the links of the chain. The gear is turned, and this pulls the chain putting mechanical force into the system. Another type of drive chain is the Morse chain, invented by the Morse Chain Company of Ithaca, New York, United States. This has inverted teeth. Sometimes the power is output by simply rotating the chain, which can be used to lift or drag objects. In other situations, a second gear is placed and the power is recovered by

attaching shafts or hubs to this gear. Though drive chains are often simple oval loops, they can also go around corners by placing more than two gears along the chain; gears that do not put power into the system or transmit it out are generally known as idlerwheels. By varying the diameter of the input and output gears with respect to each other, the gear ratio can be altered. For example, when the bicycle pedals' gear rotate once, it causes the gear that drives the wheels to rotate more than one revolution.  SPROCKETS

A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs, or even sprockets that mesh with a chain, track or other perforated or indented material. The name 'sprocket' applies generally to any wheel upon which radial projections engage a chain ing over it. It is distinguished from a gear in that sprockets are never meshed together directly, and differs from a pulley in that sprockets have teeth and pulleys are smooth. Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, and other machinery either to transmit rotary motion between two shafts where gears are unsuitable or to impart linear motion to a track, tape etc. Perhaps the most common form of sprocket may be found in the bicycle, in which the pedal shaft carries a large sprocket-wheel, which drives a chain, which, in turn, drives a small sprocket on the axle of the rear wheel . Early automobiles were also largely driven by sprocket and chain mechanism, a practice largely copied from bicycles. Sprockets are of various designs, a maximum of efficiency being claimed for each by its originator. Sprockets typically do not have a flange. Some sprockets used with timing belts have flanges to keep the timing belt centered. Sprockets and chains are also used for power transmission from one shaft to another where slippage is not issible, sprocket chains being used instead of belts or ropes and sprocket-wheels instead of pulleys. They can be run at high speed and some forms of chain are so constructed as to be noiseless even at high speed.

 BEARINGS

A bearing is machine element which s another moving machine element. The moving machine element is known as journal. Bearing permits a relative motion between the surfaces of the , while carrying the load. A certain amount of power is wasted in overcoming frictional resistance. In order to reduce frictional resistance and wear and to carry away the heat generated, lubricant may be provided. The lubricant used is usually a mineral oil refined from petroleum. The bearing block is used to hold the bearings. It is made up of cast iron. All the bearings are fitted on the machine frame. A bearing is machine element which s another moving machine element.  PULLEY A pulley is a wheel on an axle or shaft that is designed to movement and change of direction of a taut cable or belt along its circumference. Pulleys are used in a variety of ways to lift loads, apply forces, and to transmit power. In nautical contexts, the assembly of wheel, axle, and ing shell is referred to as a "block."

 ROPE A rope is a group of yarns, plies, or strands that are twisted or braided together into a larger and stronger form. Ropes have tensile strength and so can be used for dragging and lifting, but are too flexible to provide compressive strength. As a result, they cannot be used for pushing or similar compressive applications. Rope is thicker and stronger than similarly constructed cord, line, string, and twine. Rope made from metal strands is called wire rope.

 S-HOOKS

A hook is a tool consisting of a length of material that contains a portion that is curved or indented, so that this portion can be used to hold another object. In a number of uses, one end of the hook is pointed, so that this end can pierce another material, which is then held by the curved or indented portion.

 BOLT A screw, or bolt, is a type of fastener, typically made of metal, and characterized by a helical ridge, known as a male thread (external thread) or just thread, wrapped around a cylinder. Some screw threads are designed to mate with a complementary thread, known as a female thread (internal thread), often in the form of a nut or an object that has the internal thread formed into it. Other screw threads are designed to cut a helical groove in a softer material as the screw is inserted. The most common uses of screws are to hold objects together and to position objects. A screw will almost always have a head on one end which contains a specially formed shape that allows it to be turned, or driven, with a tool. Common tools for driving screws include screwdrivers and wrenches. The head is usually larger than the body of the screw, which keeps the screw from being driven deeper than the length of the screw and to provide a bearing surface. There are exceptions; for instance, carriage bolts have a domed head that is not designed to be driven; set screws often have a head smaller than the outer diameter of the screw; J-bolts have a J-shaped head which is not designed to be driven, but rather is usually sunk into concrete allowing it to be used as an anchor bolt. The cylindrical portion of the screw from the underside of the head to the tip is known as the shank; it may be fully threaded or partially threaded.[1] The distance between each thread is called the "pitch". The majority of screws are tightened by clockwise rotation, which is termed a right-hand thread; a common mnemonic device for ing this when working with screws or bolts is "righty-tighty, lefty-loosey." Screws with left-hand threads are used in exceptional cases. For example, when the screw will be subject to counterclockwise torque (which would work to undo a right-hand thread), a left-hand-threaded screw would be an appropriate choice. The left side pedal of a bicycle has a left-hand thread. More generally, screw may mean any helical device, such as a clamp, a micrometer, a ship's propeller or an Archimedes' screw water pump.

 HEX NUT A nut is a type of fastener with a threaded hole. Nuts are almost always used opposite a mating bolt to fasten a stack of parts together. The two partners are kept together by a combination of their threads' friction, a slight stretch of the bolt, and compression of the parts. In applications where vibration or rotation may work a nut loose, various locking mechanisms may be employed: Adhesives, safety pins or lockwire, nylon inserts, or slightly oval-shaped threads. The most common shape is hexagonal, for similar reasons as the bolt head - 6 sides give a good granularity of angles for a tool to approach from (good in tight spots), but more (and smaller) corners would be vulnerable to being rounded off. Also It takes only 1/6th of a rotation to obtain the next side of the hexagon and grip is optimal.However polygons with more than 6 sides do not give the requisite grip and polygons with less than 6 sides take more time to be given a complete rotation.Other specialized shapes exist for certain needs, such as wing nuts for finger adjustment and captive nuts for inaccessible areas. Nuts are graded with strength ratings compatible with their respective bolts; for example, an ISO property class 10 nut will be able to the bolt proof strength load of an ISO property class 10.9 bolt without stripping. Likewise, an SAE class 5 nut can the proof load of an SAE class 5 bolt, and so on. A wide variety of nuts exists, from household hardware versions to specialized industryspecific designs that are engineered to meet various technical standards.

 WASHER A washer is a thin plate (typically disk-shaped) with a hole (typically in the middle) that is normally used to distribute the load of a threaded fastener, such as a screw or nut. Other uses are as a spacer, spring (belleville washer, wave washer), wear pad, preload indicating device, locking device, and to reduce vibration (rubber washer). Washers usually have an outer diameter (OD) about twice the width of their inner diameter (ID). Washers are usually metal or plastic. High quality bolted ts require hardened steel washers to prevent the loss of pre-load due to Brinelling after the torque is applied. Rubber or fiber gaskets used in taps (or faucets, or valves) to stop the flow of water are sometimes referred to colloquially as washers; but, while they may look similar, washers and gaskets are usually designed for different functions and made differently. Washers are also important for preventing galvanic corrosion, particularly by insulating steel screws from aluminium surfaces. The origin of the word is unknown; the first recorded use of the word was in 1346, however the first time its definition was recorded was in 1611.

Chapter 4 EXPERIMENTAL MODEL

Chapter 5 CONCLUSION All the objectives and likewise procedures were completed to make this screw jack powered hand forklift. The production techniques used in the process were cutting, welding, drilling, grinding, threading, turning, and mechanical fastening. The forklift serves its purpose of lifting considerable amount of weights and transporting them over short distances. The dimensions were decided keeping in mind comfort and ease of transportation of the load. We successfully implemented various production techniques to achieve the objective of our project. After completing the project, conclude that our project is simple in construction and compact in size for use. Manufacturing of machine is easy and cost of the machine is less.

Chapter 6 REFERENCES 1. www.stanford.edu/~piyushk/The%20Kattwyk%20Bridge.pdf 2. www.engineeringminiprojects.com/mechanicalprojects-mechanical-engineeringprojects-topics/2012/ 3. Shigley. Mischke. Budynas & Nisbett, “Mechanical Engineering Design”(2008) Ninth Edition, Tata McGraw Hill Pvt. Ltd. 4. Amitabha Ghosh, Asok Kumar Mallik(1985) Manufacturing Science, East-West Press Private Limited