Electrifying the Scissor Jack: An Engineering Innovation Case Study

This paper examines the design, development, and evaluation of a rechargeable, battery-operated scissor jack intended for use with cars and light trucks. The study addresses key aspects of the system, including mechanical design decisions, electrical component selection, control strategy, safety features, and prototyping outcomes. A theoretical prototype incorporating a 12-V lithium-ion battery pack, a brushed DC motor with a planetary gearbox, and an integrated torque-limited controller demonstrated reliable lifting of a 1.5-ton test load, with controlled extension speed and operating temperatures maintained within safe limits. Performance testing indicated typical lift times of under 90 seconds, energy consumption consistent with multiple lifts per battery charge, and the presence of built-in safety redundancies such as mechanical locking mechanisms and current-based stall protection. Overall, the device enhances user safety, reduces physical effort, and improves efficiency for roadside tire changes and routine vehicle maintenance. The paper concludes with recommendations for scaling the design to higher load capacities, improving duty cycle and thermal management, and exploring opportunities for commercialization and real-world field testing.