FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See Section 10; rule 13)
TITLE OF THE INVENTION
Automated hydraulic Jack test setup and Testing method
APPLICANTS
TATA MOTORS LIMITED, an Indian company
Having its registered office at Bombay House,
24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India
INVENTORS
Dhinaharan Ramalingam &
Ravindra N. Babhulkar
all Indian Nationals
of TATA MOTORS LIMITED,
An Indian company having its registered office
at Bombay House, 24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India
PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner
in which it is to be performed.

FIELD OF INVENTION
The present invention relates to the automated test set up for Hydraulic jack of automobile and more particularly it relates to method of conducting test by using the same test setup thereof.
BACKGROUND OF INVENTION
Generally Hydraulic Jack is supplied with the entire range of commercial and passenger vehicles as a primary tool kit. In case of any failure in the vehicle like suspension failure, axle, tires etc., the hydraulic jack is used to lift the vehicle at a particular height. The hydraulic jack is a simple hydraulically operated mechanism with a plain or screwed ram. Conventionally, during testing of hydraulic jack the applied test load has to be maintained and adjusted by operating the jack manually, it is necessary for operating personnel to be in attendance at all times. It is not safe for an operator to work alone and accordingly the conventional test set and method for testing the hydraulic jack is expensive. The conventional test setup and the testing method for testing the hydraulic jack are complicated. It takes more time for testing the hydraulic jack using conventional setup and more over the man power required is also high. The accuracy of conducting the test is also less. Hence there is a need for an automated test setup.
OBJECTIVES OF INVENTION: -
The main object of the present invention is to provide an automated hydraulic jack test setup using two pneumatic actuators, simple linkages and micro PLC. The motive behind the invention is to provide the methods of conducting various tests of hydraulic jack using the same setup.

SUMMARY OF THE INVENTION
The embodiments herein provide an automated hydraulic jack test setup for testing the various hydraulic jacks with different capacities using servo hydraulic actuator. The test setup consists of two pneumatic actuators operated with the help of direction control valves. These direction control valve are excited with the help of micro PLC. The automated hydraulic jack test set up according to present invention comprises at least four electrically operated direction control valve to control the said pneumatic actuators. One pneumatic actuator with double acting cylinder with the inlet outlet port at both the end is required to operate the plunger. One pneumatic actuator with double acting cylinder with the inlet outlet port at both the end is required to operate the release valve. The Micro PLC is required to govern the excitation of solenoid coils of direction control valve. Two pneumatic flow control valves are required to control the output air at the time of backward stroke of both the actuators. A coupling is required to connect the different elements of the test together. Flexible hoses are provided to connect the valves with air supply and the valves with actuators. Air supply appropriate pressure is required. Electrical power supply of 220 V 35 amp for micro PLC.
According to present invention, a method of testing hydraulic jack comprises providing power supply to the said micro PLC through said connection lines, fitting hydraulic jack and other mechanical elements and linkages on the testing area, applying Load to the hydraulic jack with the help of servo hydraulic actuator or equivalent system, Lower down the jack to its lowermost position, Supplying compressed air to the system, Switching on the power supply to PLC and Repeating the above steps until the test target cycles completes.
The jack body includes a cylindrical chamber to store the oil. The required oil will be pumped inside the jack cylinder with the help of plunger. The plunger will be

operated with the help of jack handle which is provided with the jack. The release pin is provided at the center of the jack to govern the upward and downward moment of the ram. The pump will be operated with the help of operating handle. The operating handle will be inserted in the fulcrum which is connected to the plunger. The extension screw is provided at the top of the ram for fine adjustment. A servo hydraulic actuator or equivalent system is provided for applying the adequate load. The Micro PLC controlled test set up using two pneumatic actuators and simple linkages helps to reduce the time required to conduct the test. The accuracy of micro PLC will reduces the need of manpower presence during test. The said automated hydraulic jack testing setup helps to increase accuracy in conducting test reduces test time and manpower utilization.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic diagram of hydraulic jack test set up, according to
embodiment of the present invention.
FIG. 2 shows a pneumatic circuit diagram, according to present invention.
FIG. 3 shows a complete setup with servo hydraulic actuator for applying load,
according to present invention.
DETAILED DESCRIPTION OF INVENTION
Referring now to the drawings wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting the same,
The embodiments herein provide an automated hydraulic jack test set up comprising a first pneumatic actuator for controlling a pump, a second pneumatic actuator for controlling a release pin, at least four solenoid with direction control valves to control the strokes of said first pneumatic actuator and second pneumatic actuator, a

pneumatic flow control valve to control the impact of the backward stroke, a Micro PLC for communicating with said solenoid valves by supplying the excitation to the particular solenoid valve at particular time; and a flexible hoses and a quick couplings provided to connect various element in a designed manner.
The first solenoid valve is interfaced with micro PLC and first pneumatic actuator upper port for upward movement of actuator piston. The second solenoid valve is interfaced with micro PLC and first pneumatic actuator downward port for downward movement of actuator pin. The third solenoid valve is interfaced with micro PLC and second pneumatic actuator upward port for forward movement of actuator piston. The fourth solenoid valve is interfaced with micro PLC and second pneumatic actuator for backward movement of actuator pin. The first and second pneumatic actuator 2 is mounted on a bed plate 22 to support rotary moment between the plate and actuator to help the actuator to take its position while operating the jack release pin. The first pneumatic actuator piston is connected to a universal joint 6 and the universal joint 6 is connected to an operating lever 8 and the other end of said operating lever 8 is connected to a fulcrum 9 to operate a plunger 7. The universal joint 6 between the pistons and said operating lever 8 allows the required angular movement during the test. The lever arm is fixed to releasing pin to operate the release pin when said hydraulic jack 1 will reach to its maximum stroke during test. The solenoid operated direction control valves are provided with the appropriate compressed air,
According to present invention, a method of testing hydraulic jack comprises providing power supply to the said micro PLC through said connection lines, fitting hydraulic jack 1 and other mechanical elements and linkages 4 on the testing area, applying Load to the hydraulic jack 1 with the help of servo hydraulic actuator or equivalent system, Lower down the jack to its lowermost position, Supplying

compressed air to the system, Switching on the power supply to PLC and Repeating the above steps until the test target cycles completes.
Now referring to FIG. 1 and FIG. 3, the hydraulic jack test setup consist of mechanical arrangement of hydraulic jack 1 to mount on the block 5 of suitable height below the servo hydraulic actuator system 20 or equivalent system to apply adequate load during testing. The hydraulic jack 1 is to be mounted rigidly on the said mounting block 5 by using clamps to match the required height. The big cylinder 3 is to be mounted with the help of mounting plate 10 on the bed plate 22. The mounting plate 10 is be made such that after assembling the big pneumatic actuator (first pneumatic actuator) 3 on the plate there must be rotary moment between the plate and actuator. This arrangement helps the actuator to take its position while operating the jack pump. At the end of big pneumatic actuator piston the universal joint 6 is to be provided, at the other end of the universal joint 6 an operating handle with suitable length is to be fixed. The universal joint 6 between the piston and the operating handle will allows the required angular movement between them during the test. The other end of the operating lever 8 is to be fixed in fulcrum 9 to operate plunger 7. One port of the pneumatic actuator is to be connected to the solenoid valve with the help of flexible hoses for upward movement of the actuator piston. One another port of the pneumatic actuator is to be connected to the solenoid valve for downward movement of the actuator piston. The required source of compressed air is to be given to both the solenoid valves. The small pneumatic actuator (second pneumatic actuator) 2 is to be mounted on the bed plate 22 with the help of mounting plate 11. The mounting plate 11 is be made such that after assembling the small pneumatic actuator 2 on the plate there must be rotary moment between the plate and actuator. This arrangement helps the actuator to take its position while operating the jack release pine. At the end of piston of small actuator universal joint 6 to be provided, at the other end of the universal joint leaver

arrangement is to be fixed. The universal joint 6 between the piston and the leaver will allows the required angular movement between them during the test. At the end of the leaver arrangement lever arm is to be fixed further which is to be fixed in the releasing pin. This arrangement is to operate the release pin when the jack will reach to its maximum stroke during test. One of the ports of the small pneumatic actuator 2 is to be connected to the solenoid for forward movement of the actuator piston. One other end of the small pneumatic actuator 2 is to be connected to the solenoid valve for backward movement of the actuator piston. Both the solenoid operated direction control valve is to be provided with the appropriate compressed air.
Referring to FIG. 2 is the pneumatic circuit to connect solenoid valves with pneumatic actuator. The big pneumatic actuator 3 is connected with the solenoid valve 14 and 15. The small pneumatic actuator 2 is connected with solenoid valve 16 and 17. All the solenoid valves are connected electrically to micro PLC 18. The solenoid 14 is connected to the lower port of big pneumatic actuator 3 to actuate upward stroke. The solenoid 15 is connected to the upper port of big pneumatic actuator 3 to actuate downward stroke. While doing this upward and downward stroke the fulcrum 9 engaged with the operating lever 8 pumps the plunger 7. This will results in to the upward stroke of the hydraulic jack 1. After the jack reaches to its maximum position the solenoid 16 which are connected pneumatically to upper port of the small pneumatic actuator 2 tends the piston down. The lever connected to the piston will operate the release valve of the hydraulic jack 1. Due to this the hydraulic jack 1 will come to its lowermost position. Then the solenoid valve 17 will actuated which is connected to the lower port of the small pneumatic actuator 2. This tends the piston upward and the connected release valve gets closed. Again the solenoid 14 and 15 actuated alternately. The process continues for the required number of cycles.

The number of cycles covered will be recorded in the cycle counter 19. The load required to conduct the test will be applied with the help of servo hydraulic actuator or equivalent system
The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purpose of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.

We claim
1. An automated hydraulic jack test set up comprises;
a first pneumatic actuator for controlling a pump ;
a second pneumatic actuator for controlling a release pin;
at least four solenoid with direction control valves to control the strokes of
said first pneumatic actuator and second pneumatic actuator;
a pneumatic flow control valve to control the impact of the backward stroke;
a Micro PLC for communicating with said solenoid valves by supplying the
excitation to the particular solenoid valve at particular time; and
a flexible hoses and a quick couplings provided to connect various element in
a designed manner.
2. The automated hydraulic jack test set up according to claim 1, wherein said first solenoid valve is interfaced with micro PLC and first pneumatic actuator upper port for upward movement of actuator piston.
3. The automated hydraulic jack test set up according to claim 1, wherein said second solenoid valve is interfaced with micro PLC and first pneumatic actuator downward port for downward movement of actuator pin.
4. The automated hydraulic jack test set up according to claim 1, wherein said third solenoid valve is interfaced with micro PLC and second pneumatic actuator upward port for forward movement of actuator piston.
5. The automated hydraulic jack test set up according to claim 1, wherein said forth solenoid valve is interfaced with micro PLC and second pneumatic actuator for backward movement of actuator pin.
6. The automated hydraulic jack test set up according to claim 1, wherein the output from said Micro PLC is interfaced to at least two solenoid valves.
7. The automated hydraulic jack test set up according to claim 1, wherein said first and second pneumatic actuator 2 is mounted on a bed plate 22 to support rotary moment between a plate and actuator to help the actuator to take its position while operating the jack release pin.

8. The automated hydraulic jack test set up according to claim 1, wherein said first pneumatic actuator piston is connected to a universal joint 6 and said universal joint 6 is connected to an operating lever and the other end of said operating lever 8 is connected to a fulcrum 9 to operate a plunger 7.
9. The automated hydraulic jack test set up according to claim 8, wherein said universal joint 6 between the pistons and said operating lever allows the required angular movement during the test.
10. The automated hydraulic jack test set up according to claim 9, wherein said lever arm is fixed to releasing pin to operate the release pin when said hydraulic jack reaches to its maximum stroke during test.
11. The automated hydraulic jack test set up according to claim 1, wherein solenoid operated direction control valves are provided with the appropriate compressed air.
12. Method of testing hydraulic jack comprises;
applying power supply to micro PLC through a connection lines;
checking input air supply from a compressed air source;
controlling a release valve in release position;
applying an appropriate load to said hydraulic jack with the help of servo
hydraulic actuator or equivalent system;
checking a ram for lowermost position after applying load to said hydraulic
jack;
switching ON the power supply to the micro PLC ,
closing said release valve by first upward stroke of second pneumatic
cylinder;
operating said first pneumatic cylinder in upward and downward direction
with solenoid vales after closing said release valve;
firing the downward stroke of said second pneumatic cylinder once a ram of
said hydraulic cylinder reaches its maximum position;
opening the release valve to allow ram to come to lowermost position; and

repeating the above steps until the test target cycles completes.
13. The method according to claim 12, wherein said first 14 and second solenoid 15 is connected to the lower port and upper port of said first pneumatic actuator 3 to actuate upward stroke and downward stroke.
14. The method according to claim 12, wherein due to said upward and downward stroke a fulcrum 9 engaged with the operating lever 8 pumps the plunger 7 resulting in upward stroke of the hydraulic jack.
15. The method according to claim 13, wherein when said hydraulic jack reaches to its maximum position third solenoid 16 which is connected pneumatically to upper port of the second pneumatic actuator 2 tends the piston down and a lever connected to the piston will operate the release valve of the hydraulic jack as a result said hydraulic jack will come to its lowermost position.
16. The method according to claim 13, wherein when said fourth solenoid valve 17 is actuated the lower port of said second pneumatic actuator 2 tends the piston upward to close said release valve.
17. The method according to claim 13, wherein said solenoids are actuated alternately for number of cycles and the number of cycles covered will be recorded in a counter.
18. Automated hydraulic jack test set up and method of testing hydraulic jack as herein described with respect to accompanying drawings.