Development and Testing of a Low-Cost, Locally-Engineered Two-Post Car Lift for Automotive Workshops in Resource-Limited Settings

Abstract

This study presents the design, construction, and performance evaluation of a cost-effective, locally fabricated two-post car lift intended for use in small and medium-sized automotive workshops, particularly in developing regions. The system was conceptualized using a hybrid hydraulic and pulley-assisted mechanism, with structural components fabricated from locally available steel profiles. Design parameters were established through mechanical analysis and validated using finite element approximations, while performance metrics were assessed through experimental testing across three vehicle classes: compact (1,200 kg), sedan (1,600 kg), and SUV (2,200 kg). Results revealed a direct correlation between vehicle mass and lift time, with durations increasing from 18.2 s to 23.5 s as load increased. Correspondingly, vertical lift speed decreased from 11.0 mm/s to 8.6 mm/s. Structural deflection remained within elastic limits, ranging from 2.5 mm to 5.1 mm, with minimal standard deviation across trials (±0.3 mm to ±0.6 mm), confirming fabrication consistency. Lateral asymmetry remained below 2.0 mm for all test scenarios, satisfying ANSI/ALI ALCTV:2017 standards for safety and performance. The passive mechanical locking system engaged reliably under all conditions, and no mechanical failures were observed during testing. The prototype was constructed at a cost below USD 700, representing a 65–80% reduction relative to commercial imports, demonstrating the economic viability of locally engineered lifting solutions. While the thermal behavior of the motor was not directly monitored, future enhancements, including integrated thermal diagnostics, automated control systems, and structural optimization, are recommended. Overall, the project illustrates a scalable, low-cost engineering solution capable of supporting vehicle maintenance infrastructure in resource-limited settings without compromising safety or functionality.