A Project Report On: Submitted in Partial Fulfillment of The Requirement For The Award of Diploma Mechanical Engineering
A Project Report On: Submitted in Partial Fulfillment of The Requirement For The Award of Diploma Mechanical Engineering
A Project Report On: Submitted in Partial Fulfillment of The Requirement For The Award of Diploma Mechanical Engineering
Project Report on
DESIGN AND FABRICATION OF STAIR CLIMBER TROLLEY
Submitted in partial fulfillment of the requirement for the award of Diploma Mechanical
Engineering
Submitted By:
Of final year Mechanical Engineering students have submitted their project report on
Design and fabrication of stair climber trolley during academic session 2018-19 as a part
of project work prescribed by Government Polytechnic, Nagpur for partial fulfillment for
the diploma in Mechanical Engineering in sixth semester.
heavy loads over stairs. The need for such a system arises from day-to-day
requirements in our society. Devices such as hand trolleys are used to relieve the
stress of lifting while on flat ground; however, these devices usually fail when it
comes to carrying the load over short fleet of stairs. In the light of this, the
project attempts to design a stair climbing hand cart which can carry heavy
objects up the stairs with less effort compared to carrying them manually. It also
Several designs were conceived that would allow a non-industrial hand trolley
to travel over stairs, curbs, or uneven terrain while reducing the strain on the
user.
In our project, the trolley is equipped with Tri-Star wheels which enable
us to carry load up and down the stairs. It also eases the movement of trolley in
ABSTRACT
LISTOF SYMBOL5
LISTOFFIGURES6
LIST OF TABLES8
SYMBOL DEFINITION
F Force
M Bending Moment
I Moment of inertia
o Bending Stress
R Radius of Curvature
6.1 Accountstatement 25
INTRODUCTION
1. DESCRIPTION 1
HANDTROLLEY 1
TYPESOFTROLLLEY 2
WHEELEDTROLLEY 2
FOLDINGTROLLEY 2
GARDENTROLLEY 3
KITCHENTROLLEY 3
STACKTROLLEY 3
NEED FORSTAIRCLIMBERTROLLEY 3
2. STAIRCLIMBERTROLLEY 4
NEWCONCEPT 4
3.TRI-STARWHEEL 5
TRI-STARWHEELDESIGN 5
APPLICATION OFTRI-STAR
WHEEL INOURPROJECT 6
MATERIALSELECTION 7
TROLLEYBODY
Chapter 1
INTRODUCTION
HANDTROLLEY
A hand trolley is a small transport device used to move heavy loads from
one place to another. It is a very common tool used by a large number of
industries that transport physical products. Also called a hand truck or a dolly,
the hand trolley is often used by stock persons who arrange and restock
merchandise in retail stores. When used properly, trolleys can protect people
from back injuries and other health problems that can result from lifting heavy
loads.
1.1.2 Description
Professional material handlers prefer to use a hand truck when moving stackable
items such as boxes, crates or packages. Heavier items are usually
stackedonthebottomofthe hand truck, with lighterobjects saved for thetop.
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Hand truck users must be careful not to stack it so high that their vision is
blocked or the load becomes unstable. Generally, it is safe to load a hand truck
to the level of its handles or the top of the frame. The load is then shifted onto
the wheels with a backwards lifting motion. The user can maneuver the
cargo by steering it left, right or forward.
TYPES OFTROLLEY
Different types of these trolleys exist, and the type used is often chosen
based on what type of material it will move. Hand trolleys are made of various
types of hard materials, including steel, aluminum and high-impact plastic. Most
hand trolleys come in standard sizes and are used for general loads, but there are
some that are specifically designed for very small or larger products.
Wheeledtrolley
Wheeled trolleys made from stainless steel are the most common type of
hand trucks used. These are used in places with heavy loads to move, like retail
stores and factories, and typically have wheels made out of stainless steel as
well. Welded steel and metal wheel trolleys are typically much more
lightweight and are often used to carry lightermaterials.
Those with a frame and wheels made of a metal alloy are heavier and sturdily
made. Trolleys of this type usually have a wider platform for oversized loads.
Metal alloy hand trucks are typically used to transport heavy products, such as
items made of steel.
FoldingTrolley
A folding trolley is another type of hand tool, and is often made of rust-
proof aluminum. It is also lightweight but is usually able to carry heavy loads,
and can fold to take up less space when not in use. This feature also allows it to
be easily transported to places where it is needed.
2
GardenTrolley
KitchenTrolley
A kitchen trolley is a serving cart that can also be used for storage. It is
designed that it has more than one section in it which enables people to carry
various utensils and for various purposes.
SackTrolley
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CHAPTER 2
Lifting a hand truck up the stairs defeats the purpose of the device, since
the user must provide enough upward force to lift the entire weight of the cart
and its contents. Furthermore, the geometry of a hand truck makes it nearly
impossible to lift with one's legs, as is the proper form. Considerable strain is
placed on the back muscles and the risk of operator injury is sharply increased.
The pulling up of a standard hand truck up the stairs results in a bumpy and
jarring motion. This motion may damage the items loaded on the hand truck or
cause them to fall off entirely. A hand truck that could climb stairs without
requiring the user to lift would improve the safety of moving heavy objects over
irregular surfaces.
In our project, we are designing and fabricating normal hand trolleys with
Tri-Star wheel in order to enable the trolley to move up or down the stairs.
4
CHAPTER 3
TRI-STAR WHEEL
TRI-STAR WHEELDESIGN
The Tri-Star wheel was designed in 1967 by Robert and John Forsyth of
the Lockheed Aircraft Corporation. They were first developed as a module of
the Lockheed Tri star, a commercially unsuccessful amphibious military
vehicle. A Tri-Star wheel functions as an ordinary wheel on flat ground, but has
the ability to climb automatically when an impediment to rolling is encountered.
This wheel design consists of three tires, each mounted to a separate shaft.
These shafts are located at the vertices of an equilateral triangle. The three
shafts are geared to a fourth, central shaft (to which a motor may be attached).
When geared in this quasi-planetary fashion, these triangular sets of wheels can
negotiate many types of terrain, including sand and mud; they can also allow a
vehicle to climb over small obstructions such as rocks, holes, and stairs. The
wheel assembly may be gear-driven, with two wheels in rolling contact with the
ground. The third wheel idles at the top until the lower front wheel hits an
obstruction. The obstruction prevents the lower front wheel from moving
forward but does not affect the motion of the driving axle. This causes the top
wheel to roll forward into position as the new front wheel. This wheel usually
lands on top of the obstruction and allows the rest of the assembly to vault over
the obstruction. Tri-Star wheel in motion is shown in figure3.1.
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CHAPTER 4
MATERIALSELECTION
MildSteel
Mild steel, also called as plain-carbon steel, is the most common form of
steel because its price is relatively low while it provides material properties that
are acceptable for many applications, more so than iron. Low-carbon steel
contains approximately 0.05–0.3% carbon making it malleable and ductile. Mild
steel has a relatively low tensile strength, but it is cheap and malleable; surface
hardness can be increased through carburizing. It is often used when large
quantities of steel are needed, for example as structural steel. The density of
mild steel is approximately 7850 kg/cm3 and the Young's modulus is 210 GPa
(30,000,000psi).
Tri-Star wheelweb
Steel Type 304 is a variation of the basic 18-8 grade, Type 302, with a
higher chromium and lower carbon content. Lower carbon minimizes chromium
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carbide precipitation due to welding and its susceptibility to inter-granular
corrosion. In many instances, it can be used in the “as-welded” condition, while
Type 302 must be annealed in order to retain adequate corrosion resistance.
Type 304L is an extra low-carbon variation of Type 304 with a 0.03%
maximum carbon content that eliminates carbide precipitation due to welding.
As a result, this alloy can be used in the ”as-welded“ condition, even in severe
corrosive conditions. It often eliminates the necessity of annealing weldments
except for applications specifying stress relief. It has slightly lower mechanical
properties than Type304.
BEARINGSELECTION
Ball bearing
A ball bearing is a type of rolling-element bearing that uses balls to
maintain the separation between the bearing races. The purpose of a ball bearing
is to reduce rotational friction and support radial and axial loads. It achieves this
by using at least two races to contain the balls and transmit the loads through
the balls. In most applications, one race is stationary and the other is attached to
the rotating assembly. As one of the bearing races rotates it causes the balls to
rotate as well. Because the balls are rolling they have a much lower coefficient
of friction than if two flat surfaces were sliding against eachother.
Selecting a ball bearing with minimum inner diameter of 30mm,
minimum load carrying capacity of 50kg radially and speed greater than
100rpm
Bearing Selected - SKF 6006 Open Deep Groove Ball Bearing
30x55x13mm
Inside Diameter: 30mm
Outside Diameter: 55mm
Width: 13mm
8
This 6006-2RS 30x55x13-millimeter sealed ball bearing has deep groove
geometry for high speeds and supporting both radial and axial loads. This bearing
has rubber seals on both sides of the bearing to keep lubricant in and contaminants
out, and comes pre-lubricated from the manufacturer so that no additional
lubrication is required. This deep groove sealed ball bearing is for use in
applications that involve combined radial and axial loads, and a need for high
running accuracy at high rotational speeds. Such applications include clutches,
drives, gearboxes, compressors, pumps, turbines, and printing and textile
machines, among others.
WHEELSELECTION
Types of WheelMaterial
Filledrubbers
In tyres rubbers are usually filled with particles like carbon black or
silica. They consist of a tread and a body. The tread is the part of the tire that
comes in contact with the road surface. The portion that is in contact with the
road at a given instant in time is the contact. Treads are often designed to meet
specific product marketingpositions.
Polyurethane
Steel is an alloy of iron, with carbon being the primary alloying element,
up to 2.1% by weight. Carbon, other elements, and inclusions within iron act as
hardening agents that prevent the movement of dislocations that naturally exist
in the iron atom crystal lattices.
Staticfriction
The surface of the wheel and what it is rolling on are not perfectly
smooth. They have irregularities shown in figure 4.1.
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0.9
0.8
0.7
0.6
0.5
Rubber Vs. Concrete
0.4
Polyurethane Vs. Concrete
0.3
Steel Vs. Concrete
0.2
0.1
0
Coefficient of
Kinetic Friction
Fig 4.2 Coefficient of kinetic friction of various tyre materials and concrete
surface
WHEELFRAME
A specially designed wheel frame is required to hold the three wheels
together on each side of the shaft. In the existing design, the power transmission
to the single or double wheel trolley is useless to climb the stairs due to height
factor of stairs. The design of the straight wheel frame became more
complicated and was needed to be modified with its curved- spherical shape to
give proper drive, which creates more frictional force. For these reason, three
wheel set on each side of vehicle attached with frame was introduced to provide
smooth power transmission in order to climb stairs without much difficulty.
Frame arrangement is suitable to transmit exact velocity ratio also. It provided
higher efficiency and compact layout with reliable service. Easier maintenance
was possible in case of replacing any defective parts such as nut, bolt, washer,
etc.
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Types of wheelframes
A few types of wheel frames are shown in the figure4.3, 4.4 and 4.5.
12
CAD MODEL OFTROLLEY
The cad diagrams of trolley are shown in the figure4.6, 4.7 and 4.8.
13
Fig 4.8 Isometric View
Gas cutting(Oxy-Fuelcutting)
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Pipebending
Tube bending as a process starts with loading a tube into a pipe bender
and clamping it into place between two dies, the clamping block and the
forming die. The tube is also loosely held by two other dies, the wiper die and
the pressure die. The process of tube bending involves using mechanical force
to push stock material pipe or tubing against a die, forcing the pipe or tube to
conform to the shape of the die. Often, stock tubing is held firmly in place while
the end is rotated and rolled around the die. For some tube bending processing,
a mandrel is placed inside the tube to prevent collapsing. Much of the tooling is
made of hardened steel or tooled steel to maintain and prolong the tools life.
However wherever there is a concern of scratching or gouging the work piece, a
softer material such as aluminum or bronze is utilized. Pipe bending machines
are typically human powered, pneumatic powered, hydraulic assisted, hydraulic
driven, or electricservomotor.
We have employed human powered-tube bending process to bend two
mild steel hollow pipes to make 60o bent handles.
Plasma arccutting
Plasma cutting is a process that is used to cut steel and other metals of
different thickness and sometimes other materials, using a plasma torch. In this
process, an inert gas is blown at high speed out of a nozzle; at the same time an
electrical arc is formed through that gas from the nozzle to the surface being
cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt
the metal being cut and moves sufficiently fast to blow molten metal away from
the cut. Through the application of CNC technology in industrial production,
the technology cut a wide range of high accuracy, low-cost and high efficiency.
It gradually achieves its purpose of high- tech computer numerical control
cutting, with both computer- controlled and plasma arccharacteristics.
15
We have used plasma arc cutting for cutting four stainless steel webs for
the Tri-Star wheel arrangement which is shown in figure 4.9.
Components of thesystem
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programmed in a simple cutter. Gas system Gas system include the gas pipeline,
pressure gauge, regulator, etc., which can be controlled by the control system to
realize the automatic on-off road of the gas. Mechanical operation system
Mechanical operation system consists of the beam, gear box, chassis, lifting
mechanism and other components.
Due to the high frequency of CPU and large power and high heat of hard
drive, the internal parts of the system is subjected to overheating, making the
CNC system and cutting machine unable to work normally and increases the
requirement of industrial fans for cooling. When each part is not used
efficiently during cutting edges, taking sides, linking bridge etc., it results in
thermal deformation of the various parts and consequently results in low
efficiency. Automatic cutting cannot be achieved. There are no automatic
cutting on CNC system and parameter libraries, workers can only speak of their
own experience and observation of the eye, manually adjusting and controlling,
thus it cannot effectively play productivity of the CNC cuttingmachine
WELDING
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While often an industrial process, welding may be performed in many different
environments, including open air, under water and in outer space. Welding is a
potentially hazardous undertaking and precautions are required to
avoid burns, electric shock, vision damage, inhalation of poisonous gases and
fumes, and exposure to radiation. The main Types of welding used in industry and
by home engineers are commonly referred to as MIG welding, Arc welding,
Gas welding and TIGwelding.
Arcwelding
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PROTOTYPE OF STAIR CLIMBERTROLLEY
The modified hand truck was able to climb stairs while bearing a moderate load.
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CHAPTER 5
=196.2 N
Neglect the overhang beyond welded points since the wheel provides only
negligible reaction
And ∑ M = 0
M(max) =10.07N –m
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Bending equation,
M o E
= =
I y R
nr^4
I =
4
Y=D
2
N
o=3.8
NN2
Bending stress for the given material can be assumed to be 0.66×yeild strength
Thus, the allowable bending stress for the given material is 165 N/mm^2
The calculated bending stress for the material is within the allowable bending
stress for the material,
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FORCE NECESSARY TO PULL THETROLLEY
W
x
F. x = W . y
y
F= .W
22
FORCE ANALYSIS ON WHEELFRAME
Fsinθ
F cosθ
R
(Ro2-K2)1/2
K
Resinφ
Re
Recosφ
(W1+W2)/2
23
Ro= distance of centroid from centre of wheel
W1 + W2
( − Fsin8) . k = Fcos8. ƒR2− k2
2
Recos+ = Fcos8
W1 + W2
R sin+ + Fsin8 =
e
2
W1+W2
R =J(Fcos8)2+( −Fsin8)2
e
2
W1 + W2 − 2Fsin8
tan+ =
-2Fcos8
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CHAPTER 6
ACCOUNT STATEMENT
Total
9070
25
CHAPTER 7
INFERENCE
production while moving the trolley up and down the stairs. In order to reduce
the noise production the design of the wheel frame is to be modified such that
line passing through the mid-point of the trolley wheel should pass through the
mid-point of the step. The modified wheel CAD model is shown in figure 7.1.
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CONCLUSION
Though this project had some limitations regarding the strength and built
Climbing Vehicles are concerned. During the test run of this project, it was
realized that it wouldn’t be a bad idea to consider this design for carrying heavy
commercialized to suit the needs. Though the initial cost of the project seemed
product can be fully automated and produced at a lower cost the acceptance will
in our market.
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REFERENCES
1. Dr. R.K. Bansal, A text book of Strength of Materials, Laxmi Publications (P)Ltd.
2. R.S.Khurmi,J.K.Gupta,AtextbookofMachineDesign,S.ChandPublishingHouse
(P) Ltd.
3. www.wikipedia.com
4. www.mit.edu
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