Portable Automatic Hydraulic Jack

Abstract

The portable electro-hydraulic jack is an innovative tool designed to simplify vehicle maintenance, tire changes, and emergency repairs by combining the principles of hydraulics and electrical automation. Unlike traditional manual jacks that require extensive physical effort, this advanced device provides a fast, efficient, and user-friendly solution. As this is compact and portable, it can be easily stored in car trunks or toolboxes, making it an indispensable tool for vehicle owners, mechanics, and emergency responders. The device operates using an electrically powered motor that converts rotary motion into linear motion via a crankshaft mechanism. The automated operation, controlled by a switch or remote, eliminates the manual cranking required by traditional jacks, enhancing usability and reducing effort. This state-of-the-art electro-hydraulic jack offers a practical, robust, and efficient solution for modern vehicle maintenance, meeting the growing demand for convenience and safety automotive tools

Introduction

I. Introduction

The portable electro-hydraulic jack is a modern, automated lifting tool designed to improve vehicle maintenance, tire changes, and emergency roadside repairs. It combines hydraulic lifting power with electrical automation to offer a faster, safer, and more user-friendly alternative to manual jacks. Its compact, lightweight design allows easy storage and portability, making it ideal for everyday drivers, mechanics, and emergency responders.

Key benefits:

• Effortless vehicle lifting with a switch or remote control

• Enhanced safety with stable and controlled lifting

• Suitable for a wide range of users and vehicle types

II. Literature Survey

The review of previous research and designs highlights key advancements in automated lifting systems:

1. Ajayi (2019) – Compared manual vs. automatic pallet jacks, proving higher speed and efficiency with automation.

2. Wosu & Ijeoma (2024) – Developed a cost-effective hydraulic jack with locally sourced materials and DC motor.

3. Nadzri & Harudin (2023) – Created a 12V scissor jack with added tire inflation, targeting user-friendliness.

4. Agrawal et al. (2018) – Converted manual jacks to electric using car batteries, improving ease and control.

5. Frederick et al. (2014) – Optimized a portable electric jack using Pascal’s Law, focusing on safety and telescopic operation.

III. Methodology

The project followed a structured approach from problem identification to prototype testing:

Design Process:

• Component Design: Using CAD tools to create a lightweight yet strong design

• Hydraulic Integration: Cylinder and pump system calculated to lift vehicles safely

• Electrical Automation: DC motor powers the hydraulic pump, activated via a switch or remote

• Safety Features: Overload protection, limit switches, and emergency shut-offs

• Prototyping & Testing: Validated through performance testing (load capacity, lift speed, safety)

Working Principle (Flowchart Summary):

1. Power ON → 12V DC motor starts

2. Motor powers the hydraulic pump

3. Pump builds pressure → Jack lifts vehicle

4. Limit switch stops lift at max height

5. Lowering: Valve opens → pressure releases → jack descends smoothly

IV. Hardware Overview

A. Hydraulic Jack (3-ton capacity):

• Key Parts: Piston, cylinder, check and release valves, base and saddle plates

• Specifications:

  • Lift range: 190mm to 350mm

  • Material: High-strength steel

  • Weight: 5–7 kg

  • Use: Suitable for SUVs, trucks, and general industrial applications

B. 12V Permanent Magnet DC Motor:

• Specs:

  • Voltage: 12V

  • Power: 15W–50W

  • Torque: 0.3–1 Nm

  • Speed: 30–60 RPM

  • Efficiency: 60–75%

  • Size: Compact, 0.5–1 kg

V. Mathematical Calculations & Fabrication

Key Calculations:

• Vehicle weight per wheel: 3433.5 N

• Required lift speed: 0.00833 m/s

• Power to lift wheel: 28.59 W

• Motor output power: 149.8 W
  → Conclusion: Motor power exceeds lifting requirement, ensuring reliable operation.

Fabrication Process:

1. Frame Construction: Welded steel base frame

2. Mounting Hydraulic Jack: Welded onto one end of the frame

3. Mounting Motor: Fixed 20mm from the jack using C-clamp and bolts to ensure stability

Conclusion

The portable automatic hydraulic jack was successfully designed and fabricated to simplify vehicle lifting operations. It significantly reduces manual effort by integrating an electric motor with a hydraulic mechanism. The system is compact, efficient, and capable of lifting up to 3 tons with increased speed and safety. Testing demonstrated improved lift height and reduced time compared to conventional jacks. The motorized system proved reliable and user-friendly, especially in emergency scenarios. Overall, the work achieved its objectives of automation, portability, and enhanced lifting efficiency.

References

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Copyright

Copyright © 2025 Sukanya H N, Varun H G, Shivarudrayya I Dharawadmath, Sanjeevini R, Nandini B S. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.