Professional Design Project

Professional Design Project PDP‐10‐046
To design hydraulic power tools for rescue and safety for
Fire, Police, Railways, Municipalities and Military rescue
departments
p
addressingg accidents and natural calamities.
MSME name City State Zone -
Shrikrishna agro equipment pvt ltd.
Pune
Maharashtra
West
Designer/Firmg
Automotif
City Pune
State Maharashtra
PROJECT CODE
Rs.716000
Approved cost :
02-06-2011
Start Date :
Completion date : 13-12-2011
PHASE 1 – RESEARCH
Hydraulic Rescue Tools
For,
Shri Krishna Agro Equipments Pvt. Ltd.
In association with
GOI-NID Design Clinic Scheme for MSME
25 -02 -2012
Prepared by,
Mr. Sanket Kothekar, Mr. Kunal Gaurav
AUTOMOTIF
Pune
Phase I
Literature & User Study
1. Introduction to Rescue Tools
Vehicle extrication is the process of removing the vehicle from around a person that
has been involved in a motor vehicle accident, when conventional means of exit are
impossible or unadvisable.
Hydraulic rescue tools are used by emergency rescue personnel to assist vehicle
extrication of crash victims, as well as other rescues from small spaces. These tools include
cutters, spreaders, door busters and rams.
Previously rescuers often used circular saws for vehicle extrication, but these
suffered from several drawbacks. Saws can generate sparks, which could start a fire,
create loud noise, which could stress the victim, and are often slow. Alternatively, rescuers
could try to pry open the vehicle doors with a crowbar or Halligan bar, but this could
compromise the stability of the vehicle, injure the victims further, or inadvertently trigger
the airbags of the vehicle.
In comparison, hydraulic rescue tools are quieter, faster, and more versatile: they
can cut, open, and even lift a vehicle.
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AUTOMOTIF, Pune. INDIA
2.Types of Rescue Tools
a. Cutter :
The cutter is a hydraulic tool which is designed to cut through metal - a hydraulically
powered shears. These are most commonly used to cut through a vehicle's structure in an
extrication operation. Cutter blades are replaceable, and blade development progresses
as vehicle technology progresses in order to be able to cope with the new car protection
technology.
Different types of cutter blade shapes are available depending on the applications.
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AUTOMOTIF, Pune. INDIA
b. Spreader :
A spreader is a hydraulic tool designed with 2 arms which come together in a
narrow tip, and which uses hydraulic pressure to separate or spread the arms. The tip of
the tool can be inserted into a narrow gap between two vehicle panels (such as between 2
doors, or between a door and a fender) - when the tool is operated, the arms are opened,
pushing apart the metal in the panels. Spreaders may also be used to "pop" vehicle doors
from their hinges.
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AUTOMOTIF, Pune. INDIA
c. Spreader-Cutters (Combi tools)
Whilst a cutter or spreader tool is designed for a particular application, a
combination tool or combi-tool is also available which combines the cutting and
spreading functions of separate tools into a single tool. In operation, the tips of the
spreader-cutter's blades are wedged into a seam or gap and the device engaged. The
hydraulic pump, attached to the tool or as a separate unit, powers a piston that pushes the
blades apart with great force and spreads the seam. Once the seam has been spread, the
now-open blades can be repositioned around the metal. The device is engaged in reverse
and the blades close, cutting through metal. Repeating this process allows a rescuer to
quickly open a gap wide enough to pull free a trapped victim.
This operation can also be performed by dedicated spreading and cutting tools,
which are designed especially for their own operations and may be required for some
rescues. These tools sometimes have lower capabilities when compared to the dedicated
tool but may be useful where space is at a premium on fire and rescue vehicles.
d. Rams :
Rams are used far less than spreader-cutters in auto rescues; nonetheless, they
serve an important purpose. There are many types and sizes, including single-piston, dualpiston and telescopic rams. Sizes commonly vary from 50.80 cm (20") to 178 cm (70")
(extended). Rams use more hydraulic fluid during operation than spreader-cutters, so it is
essential that the pump being used have enough capacity to allow the ram to reach full
extension.
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AUTOMOTIF, Pune. INDIA
e. Power :
The tools operate on the basis of hydraulic fluid pressure of up to 720 bar, which
must be provided from a power source. There are 3 different means of generating the
pressure. The most commonly used source is a separate power unit, which is a small petrol
(gasoline) engine connected to a hydraulic pump. The hydraulic fluid is pressurised in the
pump, and conveyed in a hose under pressure to the tool.
Alternative power sources are a small electrical pump in the tool powered by a
heavy duty rechargeable battery, and a hand- or foot-operated pump also connected to
the tool directly. These are useful for lighter-duty use and do not require the storage space
taken up by the separate power unit and associated lengths of hose.
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AUTOMOTIF, Pune. INDIA
3. Market Study
a. Target Market:
Hydraulic rescue tools are used by emergency rescue personnel to assist vehicle
extrication of crash victims, as well as other rescues from small spaces. The Rescue tools
are aimed at Fire Brigade, Municipalities, Railways, Road and Building construction
departments, Highway Patrol Department, Military and Police departments.
Thses tools have universal applications so the target market is worldwide
b. Manufactures :
Currently there is no Indian Manufacturer for Hydraulic Rescue Tools but, there are
many International companies manufacturing Rescue Tools. Some of the leading
International manufacturers are ?
Holmatro
?
Genesis Rescue Systems
?
Lukas
?
Phoenix Rescue Equipments, Inc
?
Amkus Rescue Systems
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AUTOMOTIF, Pune. INDIA
4. Benchmarks
a. Holmatro
Cutter
Spreader
Combi Tool
Ram
Concrete Breaker
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AUTOMOTIF, Pune. INDIA
b. Genesis
Cutter
Spreader
Combi Tool
Ram
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AUTOMOTIF, Pune. INDIA
5. User Study
Site 1 : Central Fire Brigade Station, Pune
Central Fire Brigade Station is located in center of Pune city. During this visit we
have interacted with Officer Mr. Umratkar, Firemen Mr. Anand Das Mr. Kedari and Mr.
Pawar.
?
This Fire Brigade Station has
Fire Tender Engines
Bronto
Rescue Vans
Ambulance
: 10
:2
:2
:4
?
Rescue Van Carries following equipments
Hydraulic Spreader
Hydraulic cutter.
Hydraulic Ram
Hydraulic chain saw.
Battery operated chain and scissor.
Hydraulic cutter
Hydraulic Gay Wire
Telescopic hydraulic light master(attached to rescue van)
Gas cutter
Blower
Rubber boat
Manually operated gear box
Saw petrol operated.
24V 30 meters wire
240V 2wires 30 meters each.
440V wire 30 meters.
Self rescue device (a kit including lock release pull rope).
Pressure guage.
Safety belts.
10 kW generator operated PTO(power take off operator)
Miscellaneous tools such as hammer, axe, rope etc.
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AUTOMOTIF, Pune. INDIA
a. Cutter :
?
The available cutter is manufactured by Weber
Hydraulics.
?
It weighs about 10 - 12 kg
?
Cutter is lifted or handled with two hands during operation.
?
The center handle is place near C.G. of the cutter so that if it is held with center handle it will remain
horizontal
?
Both handles have knurled for better grip.
?
Center handle is adjustable (rotatable) so that
handle can be adjusted according to cutter
position
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AUTOMOTIF, Pune. INDIA
b. Spreader :
?
Manufacturer : Weber Hydraulics, Germany
?
Weight : about 20 Kg
?
Capacity : 5 Tons
Handling
2
a
1
b
?
Three handles positions, two at center (a) and another at end (b), are provided for better handling
and control of spreader
?
Two handles at center are provided ( 1 & 2)to be able to handle spreader in vertical and horizontal.
?
Three handles positions, two at center and another at end, are provided for better handling and
control of spreader.
?
Two handles at center are provided to be able to handle spreader in vertical and horizontal.
?
Center Handle is provides near C.G of the spreader so that when lifted with single hand it will
remain in horizontal position.
?
Spreader due to its weight is carried in wooden open box in Rescue Van for ease of taking out and
putting it in the Van
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AUTOMOTIF, Pune. INDIA
Operating Knob
?
Push buttons for opening and closing Spreader Jaws
Attachments
?
By attaching chain to its jaws, with end tied with some stable object like tree, spreader can also be
used to pull vehicles or objects.
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AUTOMOTIF, Pune. INDIA
c. Combi Tools :
?
Manufacturer : Lukas
?
Weight : about 10 Kg
?
Combi toolavailable was battery operated.
?
Shoulder Strap provided so that maximum load is taken on shoulder and hands can be free to
operate the tool.
?
Round knob for opening and closing the Jaws of the tools
c. Rams :
?
Manufacturer : Lukas
First piston stroke
Initiation of second piston stroke
?
The Ram has two pistons that lift the object.
?
After first piston is entirely out to its length, the second piston starts lifting up.
?
Round knob for opening and closing the piston of the tools
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AUTOMOTIF, Pune. INDIA
e. Lifting Bags :
?
Manufacturer : Lukas and Holmatro
?
Lifting Weight : 30 Ton
?
Pneumatic operated Lifting Bags are used to lift an object when there is very little space for
inserting lifting equipments.
?
To achieve more height lifting bags can be kept on top of other.
f. Other observations :
?
When the electric or DG power pack are not able to used due to lack of electricity or where these
power packs can not be taken, manual power packs are used.
?
Two type of coupling are used
1. Quick Change coupling.
2. Manual coupling
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AUTOMOTIF, Pune. INDIA
Site 2
a. Cutter :
Handling cutter :
Cutter need to carry with two hands as it
weighs about 20 to 25 kg
Handling Cutter
Adjusting cutter with job :
The cutter jaws have to be adjusted
horizontally or vertically or any other
angle depending on how the object needs
to be cut?
Adjusting Cutter to object
Cutter in operation
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AUTOMOTIF, Pune. INDIA
b. Spreader
The spreader weight is about 25 kg. It
needs to be handled with both hands.
Adjusting spreader with object
The spreader have to be adjusted to any
other angle depending on the object.
Spreader in operation
Handling Spreader
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AUTOMOTIF, Pune. INDIA
c. Concrete Crusher
The breaker weight is about 25 kg. It needs
to be handled with both hands.
Handling breaker
The breaker have to be adjusted to any
other angle depending on the object.
Adjusting breaker to object
Concrete breaker in operation
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AUTOMOTIF, Pune. INDIA
6. User Study Inferences
?
Weight of the tools must be kept as low as possible without losing the strength.
?
Shoulder strap should be provides to reduce stress on the hands.
?
Press type knob is preferred over rotate type operating knob.
?
Carrying case or bag is required for Hand tools.
?
Handling safety features like gloves, goggles, mask to be provided with rescue tools.
These accessories should be easy to use.
?
Tool functional time to be minimal and effective. The hydraulic pressure should be
adjustable for all tools.
7. Reference
?
en.wikipedia.org/wiki/Hydraulic_rescue_tools
?
www.holmatro.com
?
www.lukas.com/rescue
?
www.genesisrescue.com
?
Central Fire Brigade Station, Pune
*End of report
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AUTOMOTIF, Pune. INDIA
PHASE 2 – CONCEPTS
PHASE 3 – DRAWINGS
PHASE 4 – PROTOTOTYPE
FINAL PRODUCT