Mini Automated Screw Jack with Smart

Load Monitoring System

Muhammad Bilal kamran1, Muhammad Hannan2, Arsalan Rafique3, Jahanzaib Ashraf4
¹SMME NUST, Lahore
²SMME NUST, Lahore
³SMME NUST, Kahmir
4
SMME NUST, Kashmir

1
403281; 2418402; 3426229, 4413778

Abstract—This project presents the design and development real-time load monitoring system based on sensors and
of a Mini Automated Screw Jack integrated with a Smart Load microcontrollers. The system can display load data on a
Monitoring System. Aimed at reducing manual effort and digital interface and triggering alerts or cutoffs when
enhancing operational safety, the system combines a motorized Pre-set thresholds are exceeded.
lifting mechanism with real-time load sensing using a load cell
and microcontroller. The jack automatically lifts or lowers The core innovation of this project lies in merging
loads while continuously monitoring the applied force, Mechanical design principles with embedded systems to
displaying live feedback and preventing overload through produce a lifting device that is not only effective but also
programmed limits. This compact, user-friendly solution is
intelligent. By utilizing modern components such as load
ideal for automotive and industrial use, offering improved
precision, reliability, and convenience over traditional screw cells, motor controllers, and microcontrollers (e.g., Arduino
jacks. or ESP32), the system allows users to operate the jack with
precision, monitor actual loads in real time, and ensure safety
I. INTRODUCTION through smart limit enforcement. Such integration significantly
reduces the risks of structural damage or personal injury due to
A. Definition overloading or uneven force distribution.
A Mini Automated Screw Jack is a compact, motor-driven
mechanical lifting device that utilizes a screw-thread
mechanism to raise or lower loads with minimal manual
effort. Unlike traditional screw jacks, it is equipped with an
electric motor to automate the lifting process, and often
includes control systems such as microcontrollers or sensors
to improve accuracy, safety, and ease of use. Designed for
portability and efficiency, it is commonly used in applications
where space, weight, and user convenience are critical factors,
such as automotive maintenance, compact machinery, and
light industrial setups.

B. Introduction to the project

In today’s fast-paced and technologically driven world
Figure 1: An Automated Screw-Jack
traditional mechanical systems are increasingly being
enhanced through automation, smart monitoring, and user- This report presents the complete design process, from
centric design. One such essential tool—the screw jack—has conceptualization and analysis to component selection,
long served as a reliable device for lifting and supporting manufacturing methodology, and cost estimation. Through
heavy loads in automotive, industrial, and construction detailed engineering evaluation and collaborative teamwork,
environments. However, the conventional screw jack suffers This project aims to demonstrate how classic mechanical tools
from key limitations: it relies on manual operation, lacks real- can be transformed into smart, reliable, and user-friendly
time feedback, and provides no protection against overloading, systems suited for the demands of the modern age.
leading to inefficiencies, safety concerns, and possible
mechanical failure.

This project aims to address these limitations by designing and

developing a Mini Automated Screw Jack with a Smart
Load Monitoring System. The objective is to create a
compact, portable lifting solution that combines mechanical
strength with intelligent electronics to provide both automation
and safety. This is achieved by integrating an electric drive
mechanism for automatic lifting and lowering, along with a
 II. LITERATURE REVIEW Therefore, this project builds upon the established literature
by combining a miniaturized, motorized screw jack with
The screw jack has been a cornerstone of embedded real-time load monitoring. This integration aligns
mechanical lifting applications for over a century with current trends in mechanical automation, Internet of
due to its simplicity, durability, and mechanical Things (IoT) applications in maintenance tools, and user-
advantage. Traditionally used in automotive and Focused design innovation.
industrial sectors, manual screw jacks provide a
reliable means of lifting heavy loads with III. DESIGN PARAMETERS
minimal complexity. However, as industries
increasingly move toward automation and A. Objectives
intelligent systems, significant attention has been
given to upgrading conventional lifting The objective is to design a compact, motorized screw jack that:
systems with motorization and embedded smart  Automates lifting and lowering loads.
technologies.
 Integrates load monitoring to avoid overloading.
 In the study by Raut and Waghmare (2017), a  Displays real-time load information.
mechanical screw jack was enhanced using a DC
motor drive, significantly reducing the manual effort  Ensures safety, reliability, and portability.
required in lifting operations. Their findings
emphasized the feasibility of motorizing compact
lifting systems without compromising structural
B. Working Principle
strength [1]. Similarly, research by Patel and Patel
(2016) demonstrated the effectiveness of integrating a
gear mechanism with a motor to automate the screw The working principle of the Mini Automated Screw Jack is
jack for car lifting applications, highlighting based on the conversion of rotational motion into linear motion
improvements in both time efficiency and operator using a power screw mechanism. At its core, the system
safety. [2] employs a lead screw or trapezoidal screw thread connected to
an electric motor, which generates controlled rotational motion.
 The integration of load monitoring systems into As the motor turns the screw shaft, the nut fixed to the load
mechanical devices has also seen substantial platform translates this rotation into linear displacement,
advancement. According to Zhang et al. (2019), load enabling the lifting or lowering of the load.
cells and strain gauges can be accurately used to
detect real-time axial loads, allowing engineers to To enhance safety and user control, a smart load monitoring
prevent system overloading [3]. Moreover, system is integrated into the design. A load cell sensor is
microcontrollers like Arduino and ESP32 offer cost- placed beneath the lifting platform to continuously measure the
effective platforms for integrating sensors and axial force being applied during operation. This sensor feeds
actuators, as supported by Kumar and Singh (2021), real-time data to a microcontroller unit (MCU), such as an
who proposed an Arduino-based overload protection Arduino, which processes the signals and compares them against
system for hydraulic lifting machines. [4] predefined safety thresholds.

 Timken and SKF’s industrial handbooks have long The system displays the load data on an LCD or digital
advocated the importance of load awareness in interface, allowing the user to monitor the lifting process
rotating and lifting systems, pointing out that lack of visually. If the load exceeds the safe operating limit, the
monitoring often results in catastrophic failures in microcontroller can automatically stop the motor or trigger an
mechanical operations (Timken, 2020; SKF alert to prevent structural damage or failure. This feedback loop
Handbook, 2022). These documents support the not only ensures precise control but also greatly reduces the risk
inclusion of feedback mechanisms and stress analysis of overloading and mechanical stress.
in mechanical system designs. [5] [6] Power to the system is supplied either via a rechargeable battery
pack, and the operation is managed using a simple interface
 In recent years, intelligent mechanical systems— consisting of buttons or switches for upward and downward
termed “cyber-physical systems”—have emerged, movement. The combined use of mechanical efficiency,
blending sensors, control algorithms, and mechanical automated control and real-time sensing make the system
elements into a unified structure. A relevant example highly reliable, user-friendly, and suitable for both professional
is the work of Sharma and Bansal (2020), who and personal lifting applications.
developed a smart hoist mechanism using real-time
force sensing and load regulation features. Their
results demonstrated improved system longevity and
user safety, aligning directly with the goals of this
screw jack enhancement project.[7]
 C. Manufacturing Process B. Connecting Links

The completion of the project required various manufacturing

processes, as mild steel was mostly used for its construction.
Some of the Manufacturing processes which were used are as
follows: -

 Turning
 Threading
 Milling
Figure 3: Connecting Link
 Drilling
Used to connect the structure and transmit motion from one link to
 Laser cutting another link or object.
 Welding
C. Connector
These are some of the main processes that were used.

IV. 3D MODELS OF PARTS

Before the cutting and manufacturing process, the parts were

first created and analyzed using SolidWorks software to
prevent any issues. They were also tested using the software
under various loading conditions to ensure maximum.

A. Base Part

Figure 4: Connector

A non-standard Component Prepared per our need to connect the

links and provide a connection for the Lead Screw.

D. Lead Screw

Figure 5: Lead Screw

Figure 2: A Base part of the Screw Jack

Major Component of a Screw Jack which converts Rotation

Provides stability and supports the entire structure.
motion to Translation motion.
 V. SIMULATION ANALYSIS A displacement analysis was conducted to assess the
Various analyses were performed to check the reliability of the deformation behavior of the screw jack under the applied load
Project. of 500 N. The results display total displacement values (URES)
ranging from near zero at the fixed base to a maximum of
approximately 2.04 mm at the upper linkage ends. The
A. Stress analysis deformation is within acceptable limits and occurs primarily in
the load-bearing arms, as expected under vertical compression.
The smooth gradient indicates uniform load distribution and
confirms that the structure maintains its integrity without
excessive bending or distortion during operation.

VI. MANUAL ANALYSIS

Similarly, manual calculations of various parameters of the

screw Jack were also done using the MATHCAD software
due to its precise calculations and simplicity.

Figure 5: Stress analysis

A finite element analysis (FEA) was performed on the screw

Jack to evaluate the stress distribution under the applied
loading of 500 N. The simulation shows that the maximum von
Mises stress reaches approximately 1.678 × 10⁶ N/m², which is
significantly below the material’s yield strength of
3.516 × 10⁸ N/m². Stress concentrations are observed around
The top linkage joints where the load is applied, but all values
remain within safe limits. The results confirm that the design
is structurally sound and capable of handling the expected
loads without failure or permanent deformation.

A. Displacement Analysis

Figure 5: Displacement Analysis

 #include <AccelStepper.h>
#include "HX711.h"

#define HX_DT A0
#define HX_CLK A3

#define MOTOR_STEP 2
#define MOTOR_DIR 5
#define MOTOR_EN 8
#define MOTOR_ACCELERATION 400
#define MOTOR_SPEED 1000
#define MOTOR_MAX_SPEED 1500

#define LIMIT_SWITCH 9

#define CALIBRATION_FACTOR 38.0f

AccelStepper stepper(AccelStepper::DRIVER, MOTOR_STEP,

MOTOR_DIR);
HX711 scale;

String forceFirstPart = "|";

String toSend;
String command = "Stop";

unsigned long lastScaleReadTime = 0;

const unsigned long scaleReadInterval = 2000; // ms

void setup() {
pinMode(MOTOR_EN, OUTPUT);
pinMode(LIMIT_SWITCH, INPUT_PULLUP);
digitalWrite(MOTOR_EN, HIGH); // Disable motor initially

[Link](9600);
[Link](HX_DT, HX_CLK);
scale.set_scale(CALIBRATION_FACTOR);
[Link]();
delay(1000);

[Link](MOTOR_MAX_SPEED);
[Link](MOTOR_ACCELERATION);
[Link](MOTOR_SPEED);
[Link](0);
}

void loop() {
// Handle incoming serial command
if ([Link]()) {
command = [Link]('\n');
[Link](); // Clean up whitespace/newlines
}

// Handle command and motor control

if (command == "Stop") {
digitalWrite(MOTOR_EN, HIGH); // Disable motor driver
[Link](0);
[Link](); // Gracefully stop motion
}
else if (command == "Forward") {
digitalWrite(MOTOR_EN, LOW);
[Link](10000); // Move forward
}
else if (command == "Backward") {
digitalWrite(MOTOR_EN, LOW);
[Link](-10000); // Move backward
}

// Safety: Stop if limit switch is triggered

if (digitalRead(LIMIT_SWITCH) == LOW) {
[Link](0);
[Link](); // You could also call [Link](0);
}

Figure 6: Manual Calculations Using MATHCAD

[Link](); // Always call this for motion

// Read weight every 2 seconds (non-blocking)

VII. CODE ANALYSIS unsigned long currentMillis = millis();
if (currentMillis - lastScaleReadTime >= scaleReadInterval) {
lastScaleReadTime = currentMillis;

float weight = scale.get_units(1); // Faster reading

toSend = forceFirstPart + weight;
[Link](toSend.c_str()); // Print with newline for better serial
parsing
}
}
The primary purpose of this code is to operate a mini VIII. COST ANALYSIS
automated screw jack system that combines precise motor
control with real-time load monitoring, enhancing both S# Material Cost (Rs)
safety and functionality. The system is powered by a 1 Metal 1500
stepper motor controlled through the AccelStepper library, 2 Machining 1000
which allows smooth acceleration, deceleration, and speed 3 Motor 400
adjustments, critical for controlled lifting and lowering of 4 Coupler 250
heavy objects. Motor movement is managed through serial 5 Load Cell 350
commands—specifically, the system listens for "Forward", 6 Load cell Amplifier 200
"Backward", and "Stop" instructions sent via USB or 7 Bluetooth module 150
Bluetooth serial communication. Depending on the received 8 Lead Screw 800
command, the motor is either activated to move the screw
jack up or down or halted to pause the lifting process. The So, the total cost comes out to be 4650 Rs
system also integrates a limit switch, connected to a
dedicated pin, which acts as a physical safety stop to prevent
the mechanism from over-traveling or damaging itself by
forcibly stopping the motor when triggered. IX. Conclusion

Beyond motion control, the code incorporates a smart load The development of the Mini Automated Screw Jack with Smart Load
monitoring system using an HX711 load cell amplifier Monitoring System successfully demonstrates the integration of
connected to a load cell sensor. This module reads analog mechanical design and embedded electronics to enhance the
signals representing the force or weight applied to the jack functionality, safety, and user convenience of a conventional lifting
and converts them into digital values. These readings are device. By incorporating a stepper motor for automated motion and an
then calibrated using a user-defined calibration factor, HX711-based load cell system for real-time feedback, the project
which converts raw sensor output into meaningful weight bridges the gap between traditional mechanical tools and modern smart
units (e.g., kilograms or Newtons). The load value is systems. The motorized mechanism reduces manual effort while
updated and transmitted over the serial port every two ensuring precise movement, and the load monitoring feature safeguards
seconds in a non-blocking fashion, allowing real-time against overloading, providing users with an intelligent, responsive
monitoring without interrupting the motor’s operation. This system.
enables users to observe the applied load remotely, identify
The project involved a complete design cycle, including conceptual
overloading conditions, and maintain a safe operation
planning, CAD modeling, simulation-based validation, manufacturing,
window.
and coding. Structural integrity was confirmed through stress and
displacement analyses, both of which indicated the design can safely
The entire system is initialized in the setup () function, handle typical lifting loads without deformation or failure. The
where the microcontroller configures pin modes, starts serial electronic system, driven by a microcontroller, successfully interprets
communication, initializes the HX711 scale, and sets initial commands, controls the motor, and continuously monitors the applied
motor parameters like speed and acceleration. In the load, making the system robust and responsive in real-time
continuously running loop, the program checks for incoming applications.
commands, responds accordingly by adjusting motor
motion, reads sensor data at set intervals, and ensures safety The cost-effective nature of the components used, including locally
via the limit switch. Together, these integrated features available materials and open-source platforms like Arduino, makes
make the system highly suitable for applications requiring this system not only practical but also scalable for real-world use.
automated lifting, load feedback, and safety assurance, Applications of this system range from automotive servicing to
such as in portable lifting tools, automotive jacks, or compact industrial lifting scenarios, especially where safety and
compact industrial actuators. efficiency are top priorities.

Overall, this project validates the potential of smart automation in

mechanical systems and highlights how even simple tools like screw
jacks can be transformed into intelligent, user-friendly devices
through thoughtful engineering and interdisciplinary collaboration.
 X. REFERENCES
[1] Raut, A., & Waghmare, R. (2017). Design
and Fabrication of Motorized Screw Jack.
International Journal of Engineering
Research and Technology (IJERT), 6(4),
22–25.
[2] Patel, R., & Patel, D. (2016). Design and
Development of Electrically Operated
Screw Jack for Car Lifting. International
Journal of Engineering Development and
Research (IJEDR), 4(3), 933–936.
[3] Zhang, L., Wang, H., & Liu, Z. (2019).
Design and Application of Load Cell for
Structural Health Monitoring. Sensors,
19(15), 3296.
[4] Kumar, N., & Singh, A. (2021).
Microcontroller-based Overload
Protection System for Hydraulic Jack.
International Journal of Recent
Technology and Engineering, 9(6), 12–17.
[5] Timken Company. (2020). Mechanical
Power Transmission Products Manual.
Timken Technical Publication.
[6] SKF Group. (2022). SKF Handbook:
Maintenance and Reliability Best
Practices. SKF Publications.
[7] Sharma, V., & Bansal, P. (2020).
Development of a Smart Hoist System
using Real-Time Load Monitoring.
Journal of Mechanical Systems and Signal
Processing, 145, 106976.