1. APPROVAL
“I hereby declare that I have read this thesis and in my opinion this thesis is
sufficient in term of scope and quality for the award of Bachelor of Mechanical
Engineering (Design & innovation)”
Signature : …………………………
Supervisor’s Name : En Mohd Nazim Bin Abd Rahman
Date : 22 April 2011

2. DECLARATION
“I hereby, declare this thesis is result of my own research except as cited in the
references”
Signature : …………………………
Author’s Name : Muhamad Afiq Bin Muhamad Fauzi
Date : 22 April 2011

3. ii
ACKNOWLEDGEMENT
First of all, I would like to thanks ALLAH S.W.T that have given me the
opportunity to complete my „Project Sarjana Muda‟ (PSM). Alhamdulillah, His
Willingness has made it possible for me as the author to complete the PSM in time. I
worked hard in completing this project within a semester.
I would like to take this opportunity to give my special thanks to my dedicated
supervisor, En Mohd Nazim Bin Abd Rahman for guiding this project at every stage
with clarity, spending much time to discuss and help with this project, and that priceless
gift of getting things done by sharing his valuable ideas as well as share his knowledge.
I would also like to thank to all UTeM lecturers especially En. Masjuri Bin Musa, En.
Razali Md. Tith, Dr. Ir Tan Chee Fai and also the lab technician whom had helped
directly or indirectly in completing of this PSM.
Not forgotten are my best colleagues for their openhandedly and kindly guided,
assisted, and supported and also encouraged me to make this project successful. My
heartfelt thanks to my dearest family which always support and pray on me throughout
this project. Their blessing gave me the high-spirit and strength to face any problem
occurred and to overcome them rightly.
The great cooperation, kind heartedness and readiness to share worth
experiences that have been shown by them will be always appreciated and treasured by
me, thank you.

4. iii
ABSTRACT
Car jack is a device used to lift up the cars while changing the tires during an
emergency. Car jacks are available at the market has some disadvantages such as
requiring more energy to operate, are not suitable for women and cannot be used on the
uneven surface. The purpose of this project is to modify the design of the existing car
jack in terms of its functionality and also human factors considerations. In this “Projek
Sarjana Muda 1”, the scopes of research were on the designing 1.5 - 3 ton maximum
lifting capacity of car jack by using optimization concept. To optimize the existing
design, the hand lifter has been replaced by the use of pedal lever as it can reduce
energy usage. In addition, ergonomic factors are also taken into consideration in order
to reduce and simplify how to use a car jack. In the process of obtaining a suitable
design, the customer needs will be translate to the engineering characteristic to obtain
the concepts that need to be modified and fabricated. From the house of quality, the best
concept will be valued based on the weighted rating method. The morphology chart had
been used to obtain the best concept solution. After the best concept had been selected
using the weighted rating method, next step was to determine the part and component
that can be modified by arrange the part into chunks and clustering with the component
according to the function or system. From this step, it can be determined which
component can be reduced or modified. Then the configuration design was analyzed
according the function factor and critical issue so that the design that had been
implementing was according to the specification and customer requirement. The last
step for this project was parametric design. In this topic, the new design concept will be
calculated to obtain the required force and compared with the theoretical calculation in
the table of human factor.

5. iv
ABSTRAK
Jek kereta merupakan satu alat yang digunakan untuk mengangkat kereta
semasa ingin menukar tayar di waktu kecemasan. Jek kereta yang sedia ada di pasaran
mempunyai beberapa kelemahan seperti memerlukan banyak tenaga untuk beroperasi,
tidak sesuai untuk wanita dan juga tidak boleh di gunakan di atas permukaan yg tidak
rata. Tujuan tajuk ini adalah untuk mengubah suai rekabentuk jek kereta yang sedia ada
di dalam fungsinya dan juga dari segi pertimbangan faktor manusia. Di dalam Projek
Sarjana Muda 1, kajian yang dilakukan adalah untuk mengkaji setiap komponen jek
kereta dan pengubahsuaian yang boleh dilakukan oleh jek kereta kapasiti 3 tan
maksimum. Untuk mengoptimumkan rekabentuk sedia ada, penggunaan pemijak kaki
telah digantikan bagi mengantikan tuil tangan disamping itu dapat mengurangkan
tenaga yang digunakan. Selain itu, faktor ergonomik juga di ambil kira supaya dapat
mengurangkan serta memudahkan cara untuk menggunakan jek kereta. Di dalam proses
untuk mendapatkan rekabentuk yang sesuai, proses yang di ambil kira adalah daripada
kehendak pelanggan dan kemudiannya diterjemahakan kepada ciri-ciri kejuruteraan
untuk mendapatkan idea dan konsep yang perlu diubahsuai di dalam rumah kualiti.
Setelah itu jadual morfologi dibagunkan untuk memperolehi konsep pengubahsuaian
yang baru. Konsep terbaik telah dipilih dengan menggunakan kaedah penentu
tertimbang. Manakala langkah seterusnya adalah untuk menentukan bahagian-bahagian
yang boleh diubahsuai adalah dengan menetapkan bahagian menjadi potongan-
potongan dan kluster dengan komponen sesuai dengan fungsi atau sistem. Dari langkah
ini, dapat ditentukan dengan komponen dapat dikurangkan atau diubahsuai. Kemudian
rekabentuk tersebut dianalisis mengikut fungsi dan isu-isu kritikal sehingga rekabentuk
yang telah diubahsuai itu sesuai dengan spesifikasi dan keperluan pelanggan. Langkah
terakhir untuk projek ini adalah analisis rekabentuk parametrik. Dalam topik ini, konsep
rekabentuk baru akan dinilai dari segi daya yang diperlukan dan akan dibandingkan
dengan nilai teori dalam jadual.

6. v
LIST OF CONTENTS
CHAPTER CONTENTS PAGE NUMBER
ACKNOWLEDGEMENT ii
ABSTRACT iii
ABSTRAK iv
LIST OF TABLE viii
LIST OF FIGURE ix
LIST OF SYMBOL / ABBREVIATION xi
CHAPTER 1 INTRODUCTION 1
1.1 Car Jack 1
1.2 Problem Statement 2
1.3 Objective 2
1.4 PSM Flow Chart 2
1.5 Scope 4
CHAPTER 2 LITERATURE STUDY 5
2.1 Existing Car Jack 5
2.2 Hydraulic System 7
2.3 CATIA Overview 8
2.3.1 CATIA 8
2.4 Structural Analysis 9
2.4.1 Types of Structural Analysis 9
2.5 Experimental Methods for Determination of Stress 10
2.6 Numerical Methods for Analysis 11
2.6.1 Finite Elements method 12
2.7 Ergonomic 13

7. vi
2.7.1 Characteristic of Ergonomics 14
2.7.2 Cognitive Ergonomics 15
2.7.3 Physical Ergonomics 15
2.7.4 Posture 15
2.7.5 Hunkering Posture 17
2.7.6 Ergonomics Recommendations for Car Jack 18
CHAPTER 3 METHODOLOGY 19
3.1 Introduction 19
3.2 Clarifying Customer Needs 21
3.3 Specifying Customer Needs 21
3.4 Quality Function Deployment 21
3.5 House of Quality 22
3.6 Concept Generation 24
3.6.1 A Five-Step Method 24
CHAPTER 4 ENGINEERING DESIGN SPECIFICATION 26
4.1 Overview 26
4.2 Identifying Customer Needs 26
4.3 Gather raw data from customers 27
4.3.1 Survey method 27
4.4 Analysis result 28
4.4.1 Section A 29
4.4.2 Section B 31
4.4.3 Section C 32
4.5 Interpret the raw data in terms of customer needs 34
4.6 Organized the needs into hierarchy 35
4.6.1 Customer requirement 36
4.6.2 Technical requirement 36
4.6.3 House of Quality 37
4.6.4 QFD Correlation Matrix 38
4.7 Concept Generation 38
4.7.1 Design Improvements 38

8. vii
CHAPTER 5 CONCEPTUAL DESIGN 40
5.1 Product Decomposition 40
5.2 Morphological Chart 41
5.2.1 Advantages of modification 42
5.3 Concept Design 43
5.4 Concept Selected 44
5.4.1 Weighted Rating Method 44
CHAPTER 6 CONFIGURATION DESIGN 46
6.1 Generating Alternative Configurations 46
6.2 Analyzing Configuration Design 48
6.3 Evaluating Configuration Design 48
CHAPTER 7 PARAMETRIC DESIGN 49
7.1 Systematic Parametric Design 49
7.2 Human Factor Design 52
7.3 Simulation analysis 54
7.3.1 New design of foot pedal 55
7.3.2 FEA analysis for the pedal lever new concept 56
CHAPTER 8 DETAIL DESIGN 58
8.1 Assembly drawing 58
8.2 Exploded drawing 61
CHAPTER 9 CONCLUSION AND RECOMMENDATION 62
9.1 Conclusion 62
9.2 Recommendation 62
REFERENCES 64
BIBLIOGRAPHY 66
APPENDIX 67
Appendix 1 : Table of anthropometric estimates for Japanese adults 67
Appendix 2 : Questionnaires 68
Appendix 3 : Drafting Drawing 71

9. viii
LIST OF TABLE
TABLE TITLE PAGE NUMBER
Table 1 Translation of the customer statement 35
Table 2 Relative important of customer requirement 36
Table 3 Engineering characteristics 37
Table 4 Design improvement 39
Table 5 Morphological chart 41
Table 6 Weighted rating method 45
Table 7 Design factor and critical issues 48
Table 8 Hand and foot-operated control devices and their operational
characteristics and control functions 53
Table 9 Assembly View 59
Table 10 Assembly view for after improvement design 60

10. ix
LIST OF FIGURE
FIGURE TITLE PAGE NUMBER
1 PSM Flow Chart 3
2 Garage Car Jack 5
3 Hydraulic Car Jack 6
4 Scissor Car Jack 7
5 Hunkering Posture 16
6 Using the Paddle 16
7 The flow chart of the methodology for the PSM I 20
8 Example of the House of Quality 23
9 Five-step concepts 25
10 Pie chart based on gender respondents 29
11 Bar chart on the respondent‟s range of age 29
12 Pie chart for the types of vehicle by respondents 30
13 Class of vehicle bar chart 30
14 Bar chart of the respondent‟s experience on using their vehicle 31
15 Pie chart for the respondent that have change tire by themselves 32
16 Bar chart of the preferred operating system of car jack 32
17 Bar graph on the important criteria for car jack 33
18 Bar graph of the problem that faced by the user 33
19 HOQ of the design 36
20 Product Decomposition 40
21 Ratchet mechanism 42
22 Spring mechanism 42
23 Adding base area 42
24 Concept A 43
25 Concept B 43
26 Concept C 44
27 Schematic diagram 47

11. x
18 Components clustering 47
29 Hydraulic concept 49
30 Fulcrum concept diagram 50
31 Fulcrum concept diagram 51
22 a Approximate model of the knee and foreleg 52
32 b Analytical model of the knee and foreleg 52
33 Analytical diagrams of the knee and foreleg 53
34 Fulcrum concept diagram 54
35 Factor of safety analysis 55
36 New concept of pedal 55
37 Stress analysis 56
38 Displacement analysis 57
39 Factor of safety analysis 57
40 Assembly drawing 58
41 After improvement design assembly 60
42 Exploded Drawing 61

12. xi
LIST OF SYMBOL / ABBREVIATION
F = Force (N)
𝐹𝑚 = Force produce by men (N)
𝐹𝑤 = Force produce by women (N)
𝑊𝑚 = Weight average for men (kg)
𝑊𝑤 = Weight average for women (kg)
A = Area (m2
)
m = Mass (kg)
P = Pressure (N/m2
)
D = Diameter

13. 1
CHAPTER 1
INTRODUCTION
1.1 Car Jack
A jack is mechanical device used to lift heavy loads or apply great
forces. Jacks employ a screw thread or hydraulic cylinder to apply very high
linear forces. A mechanical jack is a device which lifts heavy equipment. Car
jacks usually use mechanical advantage to allow a human to lift a vehicle by
manual force alone. More powerful jacks use hydraulic power to provide
more lift over greater distance. The mechanical advantage is the factor by
which a mechanism multiplies the force or torque applied to it.
An automotive jack is a device used to raise all or part of a vehicle
into the air in order to facilitate repairs. Most people are familiar with the
basic auto jack that was still included as standard equipment with most new
cars. These days, fewer people than ever have had to use a car jack. This is
due to the continuing improvements in modern tires that have made “getting a
flat” rare. Even so, people who like to rotate their tires themselves or who
may install snow tires before the winter and remove them in the spring need
to use a jack to perform the job. (http://cotsncots.com/faq-general.html).

14. 2
1.2 Problem Statement
Nowadays in this country, most of the cars were equipped with the
scissor car jack. We found that the scissor car jack were very difficult to be
used especially by women because this types of jack needed more strength
and energy to operate this jack by turning the lead screw. Thus, we want to
develop a product based from the problem faced by the users who drive a car
regarding to this issue. To overcome this problem, a research has been
conducted to find the solution on how to design a car jack for the car using
the simplest and cheapest way while it is energy saving. Although there were
many ways to solve this problem, we recommend that the design this car jack
system is the practical way when we considered all the factors and
consequences especially about the analysis to develop this product. During
the research, we have found that most of the car user has difficulties in
maintaining their vehicles breakdown especially cars in the scope of changing
tires. The normal car jack we have in the market is operated using bare hands
and it is time consuming. It also requires much energy from the person to
rotate the jack. Hence, this report had been prepared to recommend the design
of the car jack that is user friendly and easier to operate as do not required too
much money to develop this product.
1.3 Objective
Design improvement the existing car jack in terms of its functionality
and human factor consideration.
1.4 PSM Flow Chart
Flow charts are a modelling technique introduced in the 1940/50s and
popularized for structured development in the 1970s (Gane and Sarson 1979)

15. 3
as well as project planning. Figure 1 depicts a flow chart for the project
(PSM) from the beginning until the end of the project. There are two basic
symbols on this flow chart, squares which represent activities or tasks and
arrows which represent flow of control.
Figure 1 PSM Flow Chart
Determine the Objectives and
Scopes
Problem analysis
Literature review
Study on previous
research
Study on previous
research
Create new design
Analysis of result
Problem analysis and
solutions
Discussion
Conclusion
Selecting PSM title

16. 4
1.5 Scopes
This project is about the designing and fabricating the car jack. The
types of car jack that we were used in this project were hydraulic car jack as
it is more reliable and easy to operate. In order to develop new concept of the
car jack design, we do some research on by giving questionnaire to car user.
The scopes of research were on the designing 3 ton maximum lifting capacity
of car jack by using optimization concept.
For optimizing the human power, the concepts that will be used in this
product were replacing the long arm with the leg pad. By this, the mechanical
advantage while lifting can be reducing. In our design we were using CAD to
draw out the detailed drawing of each component of our product.
Therefore, the deformation, von stress misses, and the factor of safety
of pedal lever will be analyzed using the Finite Element Analysis Software.
From our analysis, we will propose the best concept of the car jack in terms
of friendly user and lower cost in product development.

17. 5
CHAPTER 2
LITERATURE STUDY
2.1 Existing Car Jack
The most common form is a car jack, floor jack or garage jack which
lifts vehicles so that maintenance can be performed. Car jacks usually use
mechanical advantage to allow a human to lift a vehicle by manual force
alone. More powerful jacks use hydraulic power to provide more lift over
greater distances. Mechanical jacks are usually rated for a maximum lifting
capacity (for example, 1.5 tons or 3 tons). The jack shown in figure 2 is made
for a modern vehicle and the notch fits into a hard point on a body. Earlier
versions have a platform to lift on the vehicle frame or axle.
(http://en.wikipedia. org/wiki/Jack_ (device))
Figure 2 Garage Car Jack
(Photo by www.NorthenTool.com)
A hydraulic jack uses a fluid, which is incompressible, that is forced
into a cylinder by a pump plunger. Oil is used since it is self lubricating and

18. 6
stable. When the plunger pulls back, it draws oil out of the reservoir through
a suction check valve into pump chamber. When the plunger moves forward,
it pushes the oil through a discharge check valve into the cylinder. The
suction valve ball is within the chamber and opens with each draw of the
plunger. The discharge valve ball is outside the chamber and opens when the
oil is pushed into the cylinder. At this point the suction ball within the
chamber is forced shut and oil pressure builds in the cylinder.
(http://hydraulic-equipment-manufacturer.blogspot.com/p/hydraulic-
jacks.html)
Figure 3 Hydraulic Car Jack
(Photo by http://www.manufacturer.com/product/m6509561-Hydraulic+Bottle+Jack.html)
These small automotive jacks are of various different types. Bumper
jacks have a protuberance that fits into a slot under the vehicle's bumper,
providing some security against sudden sideways movement. Scissors jacks
and ratchet jacks are other kinds of hand-operated jacks. Any time a small
jack is used, it's critical that the vehicle be in a stable position on a flat
surface. Be sure that the jack is pushing up against a solid frame member that
will support the weight of the vehicle, or else you will need to repair more
than your tire. (http://cotsncots.com/faq-general.html)

19. 7
Figure 4 Scissor Car Jack
(Photo by http://www.supplierlist.com/products/balmart/shrowroom.htm)
Hydraulic or air-powered jacks are an essential component of modern
auto repair shops, and have been fixtures on the auto body repair scene for at
least 50 years. They are most often used by professional shops and garages,
although there are smaller versions that are made for the home hobbyist as
well. Hydraulic jacks operate by pressurizing water in a sealed system, which
provides more than enough power to lift a car or small truck into the air.
Once the jack has reached its full upward extension, it is locked in position so
that the under body of the vehicle is accessible for service and repairs.
(http://cotsncots.com/faq-general.html).
2.2 Hydraulic System
A hydraulic jack uses a fluid, which is incompressible, that is forced
into a cylinder by a pump plunger. Oil is used since it is self lubricating and
stable. When the plunger pulls back, it draws oil out of the reservoir through
a suction check valve into the pump chamber. When the plunger moves
forward, it pushes the oil through a discharge check valve into the cylinder.
The suction valve ball is within the chamber and opens with each draw of the
plunger. The discharge valve ball is outside the chamber and opens when the
oil is pushed into the cylinder. At this point the suction ball within the
chamber is forced shut and oil pressure builds in the cylinder.

20. 8
In a Bottle Jack the piston is vertical and directly supports a bearing
pad that contacts the object being lifted. With a single action piston the lift is
somewhat less than twice the collapsed height of the jack, making it suitable
only for vehicles with a relatively high clearance. For lifting structures such
as houses the hydraulic interconnection of multiple vertical jacks through
valves enables the even distribution of forces while enabling close control of
the lift. (http://en.wikipedia.org/wiki/Jack_(device))
2.3 CATIA Overview
CATIA is a general purpose finite element modelling package for
numerically solving a wide variety of mechanical problems. These problems
include: Static/Dynamic Structural Analysis (both linear and non-linear), heat
transfer and fluid problems, as well as electromagnetic problems. To produce
this drawing in this project, we use CATIA Version 5 Release 15 software.
Under this software, we were able to use many types of function/features
such as line, circle, trim, extrude, edit, polyline, arc, fillet, pad and others.
(Dr. R.Ganesan, 2007)
2.3.1 CATIA
Finite element analysis software enables engineers to perform the following
tasks:
 Build computer models or transfer CAD models of structures, products,
components, or systems.
 Apply operating loads or other design performance conditions.
 Study the physical responses, such as stress levels, temperature
distributions.
 Optimize a design early in the development process to reduce production
costs.

21. 9
 Do prototype testing in environments where it otherwise would be
undesirable or impossible.
2.4 Structural Analysis
Structural analysis is probably the most common application of the
finite element method. The term structural (or structure) implies not only civil
engineering structures such as bridges and buildings, but also naval,
aeronautical, and mechanical structures such as ship hulls, aircraft bodies, and
machine housings, as well as mechanical components such as pistons,
machine parts, and tools. (Chennakesava R. Alavala, 2009)
2.4.1 Types of Structural Analysis
The primary unknown (nodal degrees of freedom) calculated in a
structural analysis is displacement. Other quantities, such as strains, stresses,
and reaction forces, are then derived from the nodal displacements.
Static Analysis used to determine displacements, stresses, etc. under
static loading conditions, both linear and nonlinear static analyses.
Nonlinearities can include plasticity, stress stiffening, large deflection, large
strain, hyper elasticity, contact surfaces, and creep.
Transient Dynamic Analysis used to determine the response of a structure to
arbitrarily time-varying loads. All nonlinearities mentioned under Static
Analysis above are allowed.

22. 10
2.5 Experimental Methods for Determination of Stress
There are a number of methods that are used for finding the value of
stress in a part. Some of the methods that are most commonly used are briefly
discussed below.
Strain Gauges: A strain gauge may be defined as any instrument or
device that is employed to measure the linear deformation over a given gauge
length, occurring in the material of a structure during the loading of the
structure. This definition is quite broad; in fact it covers the range of
instruments included between the linear scale and the precise optical and
electrical gauges now available. The many types of strain gauges available
are quite varied, both in application and in the principles involved in their
magnification systems. Depending upon the magnification system, the strain
gauges may be classified as follows:
1. Mechanical
 Wedge and screw.
 Lever-simple and compound.
 Rack and pinion.
 Combination of lever and rack and pinion.
 Dial indicators.
2. Optical.
3. Interferometric type.
4. Electrical.
 Inductance.
 Capacitance.
 Resistance.
 Piezoelectric.
5. Magnetic.
6. Acoustical.
 Pneumatic.
 Scratch type.
 Photostress gauge.

23. 11
Photoelasticity: this method depends upon the property of certain
transparent solids by which they become doubly refractive under the action of
stress, the magnitude of the optical effect bearing a definite relation to that of
the stress. The optical phenomenon, known as Sir David Brewster first
discovered the “photo-elastic effect” in 1816 in sheets of stressed glass.
Brewster, however, did not succeed in obtaining a uniform stress in his model
and was not able to make any quantitative estimate of the relation between
the stress and the optical effect produced. In 1820 Biot demonstrated that a
strip of glass became doubly reflecting when set into a state of longitudinal
vibrations. Fresnel attempted to measure the changes in the velocities of the
two oppositely polarized rays in glass without any decisive results. Neumann
presented the first theory of the photoelastic effect in 1841 and expressed the
velocities of the two waves in terms of the three principal strains in the
medium. In 1853, Maxwell presented a theory in which the velocities were
related to the principal stresses. Both these theories produced relations of
precisely similar form and were equally applicable to an isotropic linear and
elastic material under any system of combined stress. (Rao, ‘The finite
element methods in Engineering’ Pergamon Press, 1982)
2.6 Numerical Methods for Analysis
In engineering analysis a theoretical model was the first choice for
researchers and scientists because of accurate and unique solution. But in
pragmatic design problem, the theoretical model was scarcely utilized to
predict physical response because of the complex geometrical design and
path. Therefore powerful numerical method was introduced to engineers to
overcome difficulty.

24. 12
Some of the numerical approaches are
 Finite difference method.
 Finite volume method.
 Boundary element method.
 Finite element method.
In the design of engineering structures, numerical simulations play an
increasingly important role. This can be attributed to the high costs or
practical difficulties related to experiments, which have to confront rapid
advances in the computational power and the resulting decrease in the costs
for computer simulations.
2.6.1 Finite Elements method
Finite element method has become a powerful tool for the numerical
solution of a wide range of engineering problems. Applications range from
deformation and stress analysis to field analysis of heat flux, fluid flow,
magnetic flux, seepage and other flow problem. In this method of analysis, a
complex region defining a continuum is discredited into simple geometric
shapes called Finite Elements. Finite element method solves for forces and
displacement over the entire object. Since most visual applications tend to be
more interested over the entire object, Finite element method seems
promising. Finite element method is used for solving many industrial
problems like Automobile frames, optimization of mechanical parts, artificial
limbs etc. Rolling mill housing is one of them.