ISSN (Online) 2581-9429

IJARSCT

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 2, Issue 8, June 2022

Impact Factor: 6.252

Design and Analysis of Two Wheel Drive

Forklift for Industrial Warehouses
Prof. G. V. Pise1, Mr. Mayur Shitole2, Mr. Suhas Marade3, Mr. Rushikesh Dhamal4, Aditya
Choure5
Assistant Professor, Mechanical Engineering, NBNSSOE, Pune, India1
UG Student, Mechanical Engineering, NBNSSOE, Pune, India2,3.4,5

Abstract: Gears are a critical element in a variety of industrial applications such as machine tools
and gearboxes. An unexpected failure of the gear may cause significant economic losses. For that
reason, fault diagnosis in gears has been the subject of intensive research. Vibration analysis has
been used as a predictive maintenance procedure and as a support for machinery maintenance
decisions. As a general rule, machines do not break down or fail without some form of warning, which
is indicated by an increased vibration level. By measuring and analyzing the machine’s vibration, it
is possible to determine both the nature and severity of the defect, and hence predict the machine’s
failure. The vibration signal of a gearbox carries the signature of the fault in the gears, and early fault
detection of the gearbox is possible by analyzing the vibration signal using different signal processing
techniques. This paper presents analysis of vibration in gears using modal analysis and FFT analysis.
It also presents analysis of gears with crack and gear with missing teeth. It also presents the analysis
of Natural frequency in steady as well as running condition.

Keywords: Gears, Fault Diagnosis, Vibration, etc.

I. INTRODUCTION
On floor, lifting heavy components or materials is a hectic job and also a risky job. Fork lift are always play an
important role for heavy duty works, if cargos are being organized properly for the use of forklifts with right
attachment would be a best way to load and unload which would make the whole process less time consuming,
the less labours intensive in addition forklifts optimize the use of storage space by eliminating the need for many
people to handle the loading and unloading operation. The value of use of internal transport square measures a
typical part of the company’s accounting, whereas the environmental consequences associated with it square
measure usually unmarked.
In many cases, significantly in very little and medium organization, there is Associate in Nursing absence of
awareness of the requirement to pay the environment fees incurred by the exploitation of internal transport suggests
that that apply to off road vehicle, like wheeled vehicle, excavators or loaders usually, the wheeled vehicle is made
public as a tool capable of lifting several kilograms of weight. A wheeled vehicle can be a vehicle form of
somewhat truck that hastwo metal forks on the front accustomed carry merchandise

II. OBJECTIVES:
1. To reduce the human efforts.
2. This machine can be used in warehouses as well as various cargo plants, airports, railway junctions.
3. There is a large scope of transportation of goods from one place to another place easily.

III. METHODOLOGY
Step 1: - We started the work of this project with literature survey. We gathered many research papers which are
relevant to this topic. After going through these papers, we learnt about car towing machine.

Copyright to IJARSCT DOI: 10.48175/IJARSCT-5534 828

www.ijarsct.co.in
 ISSN (Online) 2581-9429
IJARSCT

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 2, Issue 8, June 2022

Impact Factor: 6.252

Step2: - After that the components which are required for my project are decided.
Step 3: - After deciding the components, the 3 D Model and drafting will be done with the help of CATIA
software.
Step 4: - The components will be manufactured and then assembled together.

The testing will be carried out and then the result and conclusion will be drawn.
In this two-wheel drive fork lifting machine, we have used Arduino circuit to control the fork translation and drive
train. This Arduino circuit is used to control servo motor which controls the motion of lead screw attached to
guide the fork for upward and downward motion. Another servo motor is used to drive the unit to its required
position. Basically, the main components of this project are Fork, Lead screw which guides the fork for lifting
and lowering motion, Arduino circuit to control the drive of respective servo motors, and the base unit for the
mounting of servo motors and Arduino circuit.

III. LITERATURE REVIEW:

1) “DESIGN OF TWO WHEEL AUTOMATIC ELECTRIC FORKLIFT FOR INDUSTRY
WAREHOUSES& DOMESTIC PURPOSE”, Lakshya Garg, Nitish Chauhan, Nikhil Tyagi UG (B. Tech)
Students, Asst. Prof Department of Mechanical Engineering, Sunder Deep Engineering College, Ghaziabad.
In this research paper they have researched about two Wheel Automatic Electric forklifts, it’s a small electrical
vehicle designed to build a cheap forklift for industry warehouses& domestic purpose. A goods transportation
device which can drive by anyone. Safe movement during
picking, stacking and traveling with loads. The dynamics of the vehicle is simple to the control the vehicle which
means that it is stable. This is prevented by two small supporting wheels for balance the vehicle and its time
derivative, controlling the motors to keep the vehicle balancing.

2) “Two Wheel Aisle Forklift”, Ravi G. Kaithwas, Aniket A. Pattiwar, Rahul R. Ulmale, Ashish D. Wabhitkar UG
Student,Department of Mechanical Engineering Jawaharlal Darda Institute of Engineering &Technology,
Yavatmal, India.
In this paper they have stated that, Forklifts are designed to handle and transport both raw materials and goods
carefully and efficiently. From time to time these machines must be transported from one work site to another. A
normal sit-down forklift with the ability to lift 5,000 pounds will itself weigh as much as 9,000 pounds. The average
automobile weighs approximately 4,000 pounds. Weighing in at more than two times the weight of the average
family automobile. This paper presents research related to the choice of the criteria that can be used to fill the gap
between the forklift’s minimum capacity and works maximum capacity to lift the objects from a place to another
place in warehouse operation. The analysis had been done with the aim of exploring the requirements of warehouses
and construction sites. With some changes to forklift we designed a two-wheeler forklift, this research paper gives
an exact idea about how should be a two-wheel forklift is useful, safer and efficient in narrow passages working
sites and how to design and contrast the two-wheel aisle forklift for such working places.

3) “Design, Development and Modelling of Forklift”, Ugale Sachin , Salvi Tushar , Lanjekar Sachin , Kshirsagar
Prashant Mechanical Engineering Department, Final Year Students RMCET, Ambav, Ratnagiri,India. Assistant
Professor, Mechanical Engineering Department, RMCET, Ambav, Ratnagiri, India.
They describe the development of robotic forklift intended to operate alongside human personnel, handling
palletized materials within existing, busy, semi-structured outdoor storage facilities. The main objective of this
project is to fabricate a Mechanical forklift for material handling in industries. In this paper a robotic vehicle is
fabricated which runs to carry material from one place to another by using Radio Frequency Technology.
Nowadays in industries, forklift used with hydraulic system. To use forklift, it requires one spot guide to guide a

Copyright to IJARSCT DOI: 10.48175/IJARSCT-5534 829

www.ijarsct.co.in
 ISSN (Online) 2581-9429
IJARSCT

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 2, Issue 8, June 2022

Impact Factor: 6.252

forklift driver because of less visibility. This paper discusses how to integrate Radio frequency identification
(RFID) technology into a forklift truck to make it wireless to increase visibility and human safety.

4) “3 WHEEL DRIVE FORKLIFT FOR INDUSTRIAL WAREHOUSE” RAJAT.RAJENDRA. WADE,

DIGVIJAY. K. TAKE, MAHESH. S. DESHMUKH, PRANAW. A. RAUT Student, Department of Mechanical
Engineering Jawaharlal Darda Institute of Engineering & Technology, Yavatmal, Maharashtra, India
In today's life, there's a good type of forklifts, from the big significant loading truck to the one that works among
slim aisles. Forklifts have become one in all the fundamental transportation tools we tend to use in our lives. With
all the forklifts in existence, we discover that their square measure some enhancements that can be created to bring
the self-propelled vehicle to a much better performance. Mechanical fork raise is associate improved and advance
technology that helps caused revolution at intervals the mechanical industries these days all important engineering
company uses it. Widespread use of the wheeled vehicle truck had revolutionized deposition practiced before the
center of the 20th century. a mix of cloth handling system is at intervals the employment, actual from that entirely
physical to people who unit of measurement semi-automatic but manually controlled. self-propelled vehicle has
revolutionized warehouse work. They created to achievable for one person to maneuver thousands of pounds
promptly. Well maintained and safely operated forklifts build lifting and transporting freight infinitely easier. this
may be the ultimate description of a conventional wheeled vehicle truck. To enhances the technology any, this
image module is created with remote technology, there by the operator can walk at the facet of the wheeled vehicle
for higher visibility & the instrumentality area unit usually placed accurately (precision position). this may increase
the protection of the operator

5) “Innovative design of the lifting mechanisms for forklift trucks”, Jian-Yi Wang, Jing-Shan Zhao, Fu-Lei Chu,
Zhi-Jing Feng Department of Precision Instruments and Mechanology, Tsinghua University, Beijing 100084, PR
China.
They say Forklift truck is one of the most important tools in logistics. However, the general mast system of a forklift
truck not only restrains the driver's vision, but also increases the whole weight of a truck and decreases the fuel
economy. Therefore, this paper focuses on the innovative design of a new lifting mechanism for forklift truck.
Firstly, a spatial multi-link lift-guidance mechanism is proposed. And then, under the constraints of this
mechanism, the mobility of the fork and fork frame is investigated in theory. Lastly, a new lifting mechanism based
on it is presented and computer simulation is used to demonstrate the feasibility of motion. This multi-link lifting
mechanism takes advantage of flexible cable drive and rigid body guidance, which not only provides the operator
with a wider field of vision but also reduces the equilibrate weight of a vehicle and therefore improves the fuel
economy.
Forklift trucks are usually used at railway stations, warehouses, ports and factories for loading, unloading and
conveying. A general weight-balanced forklift truck consists of a chassis and a work device which can be tilted
and lifted vertically. However, the general forklifts have the following major disadvantages. First, the mast system
composed of several large components will badly affect the driver's field of vision because it locates in front of
the driver. Many accidents involving collisions between pedestrians and trucks are due to inherently bad
visibilities of the forklift trucks.

6) “Design and Fabrication of Battery-Operated Forklift”, Anil A. Sequeira, Saif Mohammed, Avinash A. Kumar,
Muhammed Sameer, Krishnamurthy H. Sachidananda School of Engineering and IT, Manipal Academy of Higher
Education, Dubai 345050, UAE Manipal Academy of Higher Education, Dubai 345050, UAE.
Forklift is defined as an industrial truck which is capable of lifting hundreds of kilograms. Forklift is commonly
used in warehousing and manufacturing and it consists of two metal forks at the front of the vehicle in order to lift
and transfer the load. The way the load is lifted in case of forklift is in such a way that the operator is going to
move forward the vehicle until the two forks push under the cargo and then it is lifted by operating the forks.

Copyright to IJARSCT DOI: 10.48175/IJARSCT-5534 830

www.ijarsct.co.in
 ISSN (Online) 2581-9429
IJARSCT

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 2, Issue 8, June 2022

Impact Factor: 6.252

Sometimes forks are also known as blades and made of steel and is capable to lift a few tons. The power to
operate the forklift are either given using gasoline or electricity. Electric forklift depends on batteries to operate
as compared to Gasoline or propane forklifts.
These gasoline or propane forklifts are much stronger or faster as compared to electric forklifts, but considered
to be difficult to maintain, and it is also fuel efficient.

IV. CAD DESIGN

Computer-aided design (CAD) is the use of computers to aid in the creation, modification, analysis, or
optimization of a design. CAD software is used to increase the productivity of the designer, improve the quality of
design, improve communications through documentation, and to create a database for manufacturing. CAD output
is often in the form of electronic files for print, machining, or other manufacturing operations.

COMPONENTS USED:
Lead Screw:
A lead screw (or lead screw), sometimes called a power screw or translation screw, is used to translate turning
motion into linear motion. Lead screws can be manufactured by rolling, cutting, or grinding the threads.

Figure: Lead Screw

Sprocket:
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.

Figure: Sprocket

Chain:
A bicycle chain is a roller chain that transfers power from the pedals to the drive-wheel of a bicycle, thus propelling
it. Most bicycle chains are made from plain carbon or alloy steel, but some are nickel-plated to prevent rust, or
simply for aesthetics.
Copyright to IJARSCT DOI: 10.48175/IJARSCT-5534 831
www.ijarsct.co.in
 ISSN (Online) 2581-9429
IJARSCT

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 2, Issue 8, June 2022

Impact Factor: 6.252

Figure: Chain

DC Motor:
DC motors are suitable for many applications – including conveyors, turntables and others for which adjustable
speed and constant or low-speed torque are required. They also work well in dynamic braking and reversing
applications, which are common in many industrial machines.

Figure: Motor

Arduino UNO:
Arduino of type -328P, 8-bit controller, with 4 ports, 4 analogue & 13 digital pins With Bluetooth mode HC-05.

Figure: Arduino uno

Copyright to IJARSCT DOI: 10.48175/IJARSCT-5534 832

www.ijarsct.co.in
 ISSN (Online) 2581-9429
IJARSCT

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 2, Issue 8, June 2022

Impact Factor: 6.252

Lead Screw:
Data:
Diameter of lead screw, D=20 mm
Diameter of internal diameter of wheel=d=25 Efficiency of lead screw=42%
Calculation
Lead =pitch*starts =5*1 =5mm
Therefore,
Weight to be lifted is = 10kg
So, the maximum load will be 10 kg
Torque produce on lead screw is, × × /
Torque=
× . × × . /
=
=32.79 N-mm

Chain Design:
Selecting standard chain used in cycle as Chain - 06 B From V.B. Bhandari page no. 14.3
Pitch -9.525mm

Roller diameter, d1=6.35 mm Width’ b1=5.72 mm

Transverse pitch pt.=10.24 mm Teeth (z1) = 18
z2= 44

Approximate centre distance, a = 40*P nominal

a = 40*9.525
a = 381 mm

No of links
Ln=2(a/p) + (z1+z2/2) + (z2- z1/2* )2 *(p/a)
= 2(381/9.525) + (18+44/2) + (44-18/2* )2* (9.525/381)
= 111.43 = 111mm

Length of the chain

L= Ln*p = 111*9.525 = 1057.28 mm

Design of Sprocket:
Used chain no.06B For teeth (Z)=18 Pitch, P = 9.525 mm
Width between inner plates, b1= 5.72 mm Roller diameter, d1= 6.35 mm
Transverse pitch pt =10.24 mm

1) Pitch circle diameter

/
D1= sin(180/ 1) D2= sin(180/ 2)

9.525/ sin(180/18) 9.525/ sin(180/44)

= =

Copyright to IJARSCT DOI: 10.48175/IJARSCT-5534 833

www.ijarsct.co.in
 ISSN (Online) 2581-9429
IJARSCT

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 2, Issue 8, June 2022

Impact Factor: 6.252

D1 = 54.85 mm D2 = 133.59mm

2) Roller seating radius (ri)

rimax = 0.505d1 + 0.069* (d1)1/3 rimax = 3.33mm
rimin = 0.505 d1 = 3.2mm
3) Tooth Flank Radius (re)
remax = 0.008(z2+180) =16.928mm
remin = 0.12*d1(z+2) = 15.24mm

4) Root Diameter (Df)

Df = D – 2* ri = 88.47mm

5) Tooth height above pitch polygon (ha)

hamax = 0.625*p – 0.5*d1 +0.8*p/z = 2.9513mm hamin = 0.5(p-d1) = 1.5875mm

6) Tooth Width (bf)

bf = 0.93 *b1 = 5.3196mm

7) Tooth Side Relief (ba) ba = 0.1p to 0.15p = 1.1907mm

For Calculation:
Fork lift:
Considering Uniformly distributed load over cantilever beam

For calculating the S.F.D and B.M.D for the fork,

we are going assume the load as 10kg which is = 10x9.81= 98.1N of load is distributed over the span of the fork
after this conceptual calculation we are going to do the actual calculation while developing the project according
to requirement.

Copyright to IJARSCT DOI: 10.48175/IJARSCT-5533 834

www.ijarsct.co.in
 ISSN (Online) 2581-9429
IJARSCT

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 2, Issue 8, June 2022

Impact Factor: 6.252

Motor:
We have to lift 10kg of load and we know torque required for lead screw is 32.79 N-mm And for the drive we
have assumed that the force carried by the motor is 20kg
So, therefore force = (20*9.81) =196.2 N
The distance between the driven sprocket and the prime mover is 350mm Torque = 196.2 x 350
= 68670 N-mm= 68.70 N-m

GEOMETRY:

MATERIAL PROPERTIES:

MESH:
ANSYS Meshing is a general-purpose, intelligent, automated high-performance product. It produces the most
appropriate mesh for accurate, efficient multi physics solutions. A mesh well suited for a specific analysis can be
generated with a single mouse click for all parts in a model. Full controls over the options used to generate the
mesh are available for the expert user who wants to fine-tune it. The power of parallel processing is automatically
used to reduce the time you have to wait for mesh generation.

Copyright to IJARSCT DOI: 10.48175/IJARSCT-5533 835

www.ijarsct.co.in
 ISSN (Online) 2581-9429
IJARSCT

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 2, Issue 8, June 2022

Impact Factor: 6.252

Nodes and Elements:

V. STATIC STRUCTURAL ANALYSIS

Boundary Conditions:
A boundary condition for the model is the setting of a known value for a displacement or an associated load. For a
particular node you can set either the load or the displacement but not both. The main types of loading available in
FEA include force, pressure and temperature. These can be applied to points, surfaces, edges, nodes and elements
or remotely offset from a feature. The way that the model is constrained can significantly affect the results and
requires special consideration. Over or under constrained models can give stress that is so inaccurate that it is
worthless to the engineer. In an ideal world we could have massive assemblies of components all connected to
each other with contact elements but this is beyond the budget and resource of most people. We can however, use
the computing hardware we have available to its full potential and this means understanding how to apply realistic
boundary conditions.

Figure 8.1: Boundary Conditions

Copyright to IJARSCT DOI: 10.48175/IJARSCT-5533 836

www.ijarsct.co.in
 ISSN (Online) 2581-9429
IJARSCT

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 2, Issue 8, June 2022

Impact Factor: 6.252

VI. RESULTS AND PLOTS: TOTAL DEFORMATION

The total deformation is observed to be 0.2526mm

EQUIVALENT STRESS:

The equivalent stress is observed to be 2.5339 MPa which is less than the yield strength of the material which is
250 MPa so the fork design is safe.

Copyright to IJARSCT DOI: 10.48175/IJARSCT-5533 837

www.ijarsct.co.in
 ISSN (Online) 2581-9429
IJARSCT

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 2, Issue 8, June 2022

Impact Factor: 6.252

REFERENCES
[1] “DESIGN OF TWO WHEEL AUTOMATIC ELECTRIC FORKLIFT FOR INDUSTRY
WAREHOUSES& DOMESTIC PURPOSE”, Lakshya Garg, Nitish Chauhan, Nikhil Tyagi UG (B. Tech)
Students, Asst. Prof Department of Mechanical Engineering, Sunder Deep Engineering College,
Ghaziabad.
[2] “Two Wheel Aisle Forklift”, Ravi G. Kaithwas, Aniket A. Pattiwar, Rahul R. Ulmale, Ashish D. Wabhitkar
UG Student,Department of Mechanical Engineering Jawaharlal Darda Institute of Engineering
&Technology, Yavatmal, India.
[3] “Design, Development and Modelling of Forklift”, Ugale Sachin , Salvi Tushar , Lanjekar Sachin , Kshirsagar
Prashant Mechanical Engineering Department, Final Year Students RMCET, Ambav, Ratnagiri,India.
Assistant Professor, Mechanical Engineering Department, RMCET, Ambav, Ratnagiri, India.
[4] “3 WHEEL DRIVE FORKLIFT FOR INDUSTRIAL WAREHOUSE”, RAJAT.RAJENDRA. WADE,
DIGVIJAY. K. TAKE, MAHESH. S. DESHMUKH, PRANAW. A. RAUT Student, Department of
Mechanical Engineering Jawaharlal Darda Institute of Engineering & Technology, Yavatmal, Maharashtra,
India
[5] “Innovative design of the lifting mechanisms for forklift trucks”, Jian-Yi Wang, Jing-Shan Zhao, Fu-Lei Chu,
Zhi-Jing Feng Department of Instruments and Mechanology, Tsinghua University, Beijing 100084, PR
China.
[6] “Design and Fabrication of Battery-Operated Forklift”, Anil A. Sequeira, Saif Mohammed, Avinash A.
Kumar, Muhammed Sameer, A. Kareem, Krishnamurthy H. Sachidananda School of Engineering and IT,
Manipal

Copyright to IJARSCT DOI: 10.48175/IJARSCT-5533 838

www.ijarsct.co.in