“DESIGN AND FABRICATION OF AUTOMATIC TROLLEY”

BY

SAURYA PRAKASH SINGH (1603040086)

SHIKHAR AGRAHARI (1603040087)

SHUBHAM CHAUHAN (1603040094)

AYUSH RAWAT (1703040902)

Guided by

Dr. A.P. SINGH

Dr. SHUBHASH MISHRA

Department of
MECHANICAL ENGINEERING

INDERPRASTHA ENGINEERING COLLEGE

63, Site Nagar, Flyover Road, Sahibabad Ghaziabad
Affiliated to DR. A.P.J ABDUL KALAM TECHNICAL UNIVERSITY
LUCKNOW UTTAR PRADESH

May 2020

i
“DESIGN AND FABRICATION OF AUTOMATIC TROLLEY”

By

SAURYA PRAKASH SINGH (1603040086)

SHIKHAR AGRAHARI (1603040087)

SHUBHAM CHAUHAN (1603040094)

AYUSH RAWAT (1703040902)

Submitted in partial fulfilment of the requirement for the Degree of Bachelor Technology in
MECHANICAL ENGINEERING

INDERPRASTHA ENGINEERING COLLEGE, GHAZIABAD

APJ ABDUL KLAM TECHNICAL UNIVERSITY LUCKNOW,
MAY-2020

ii
 CERTIFICATE

This is to certify that Project Report Entitled “DESIGN AND FABRICATION OF

AUTOMATIC TROLLEY” Which is submitted by “Saurya Prakash Singh, Shikhar
Agrahari , Shubham Chauhan and Ayush Rawat” in partial fulfillment of the requirement for
the award of B.Tech. degree in Department of Mechanical Engineering of APJ Abdul Kalam
Technical University Lucknow, is a record of candidate’s own work carried out by him under
my/ our supervision. The matter embodied in this report is original and has not been submitted
for the award of any other degree.

Date: Project Guide\ Co. Guide

Dr. A.P.SINGH (Asso. Prof.)\

Dr. SHUBHASH MISHRA (Asso. Prof.)

iii
 DECLARATION

We hereby declare that this submission of our own work and that, to the best of my knowledge
and belief, it contains no material previously published or written by another person, not material
which to a substantial extent has been accepted for the award of any other degree or diploma of
the university or other institute of higher learning, except where due acknowledgement has been
made in the text.

Signature:
Name: SAURYA PRAKASH SINGH
Roll No: 1603040086
Date:

Signature -
Name: SHIKHAR AGRAHARI
Roll No: 1603040087
Date:

Signature:
Name: SHUBHAM CHAUHAN
Roll No: 1603040094
Date:

Signature:
Name: AYUSH RAWAT
Roll No: 1703040902
Date:

iv
 ACKNOWLEDGEMENT

We wish to express our since thanks to the people who extended their help during the course of
our project.

We are greatly and thankful to our honorable Director, Dr. B.C. Sharma Sir for facilitating this
opportunity. We also record our sincere thanks to our Head of Department, Dr. H.K. Rai Sir, for
his kind support to take up this project.

We would like to extend our sincere thanks to our dynamic guide and co-guide
Dr. A.P. SINGH Sir & Dr. SHUBHASH MISHRA Sir for his constant technical support and
encouragement, which enable us to complete our project successfully.
We are thankful to Dr. Bhaskar Kandpal Sir for rendering moral support to us during the
course of our project. We are also thankful to Mr. B.M. Sharma Sir for encouraging support
and useful suggestion during this work

We also express our sincere gratitude to all the faculty members of workshopfor their moral
support throughout this Project.

Last but not the least; we thank our parents who have been the source of inspiration and support
for us throughout this project work. We also thank all those who have either directly or indirectly
helped during this project work

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 ABSTRACT
Despite rapid changes in the way the things are being manufactured, we are still used to the age
of techniques of manufacturing. The reasons are multifold ranging from inertia, rejection of the
new technologies, lack of engineering aptitude, lack of skill & technical know-how and most
importantly fear of losing employment opportunities. This project aims at developing a
mechanism for easy transportation of heavy loads over a plane surface with less effort.

Fig: Trolleys
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 but the motored
operated hand trolley are reduce the effort of users and also make them stress free. In the light of
this, the project attempts to design a motor-operated hand cart which can carry heavy objects on
the plane surface with less effort compared to carrying them manually. In present project, the
trolley is equipped with motor operated wheel which enable us to carry load and also easy the
movement of trolley in surfaces. .Present paper deals with design and fabrication of industrial
trolley which can be used to transfer luggage or items from one place to another place. A trolley
now days are important for transferring different items from place to place in our daily life or
even in working life as per the requirement. The trolley has been designed using AUTOCAD and
SOLIDWORK
Keywords: Try-star Wheel, Cluster, Hybrid Motors, Belts, Gears

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 LIST OF SYMBOLS

SYMBOL DEFINITION
F Force
M Bending Moment
R1,R2 Reaction Force
I Moment of Inertia
σ Bending Stress
y Distance between mid-point weight
and trolley wheel axis.
E Young’s Modulus
R Radius of Curvature
X Height of the trolley
Y Distance Between neutral axis and
Trolley wheel axis
W Weight acting on the trolley
W1 Weight of object to be carried
W2 Weight of the trolley
Re Reaction force on one side
TT Total Tractive Effort
RR Rolling Resistance
GR Gradient Resistance
FA Acceleration Force
P Power
T Torque
W Angular Velocity
RF Resistance Factor
a Acceleration
m Mass
GW Gross Weight
r Radius
α Inclination angle
ta Time required to attain maximum
speed
µ Coefficient of Rolling Friction

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 CONTENTS

1. INTRODUCTION………………………………………………………..1-3
1.1 OVERVIEW
1.2 AREA OF USE
1.3 PROBLEMS IDENTIFICATION
1.4 EFFECT ON ENVIRNOMENT
1.5 SCOPE
1.6 NEEDS AND IMPORTANCE

2. BACKGROUND OF TOPIC……………………………………………...4

3. LITERATURE STUDY……………………………………………..….5-11
3.1 TROLLEY TYPES, FUNCTION AND TECHINICAL REVIEW
3.1.1 Traditional Shopping Trolley
3.1.2 Rubbermaid Commercial Trolley
3.1.3 Hospital Trolley
3.1.4 Baby Trolley
3.1.5 Multipurpose Trolley
3.1.6 Stanchion Trolley
3.1.7 Multi-Functional Instrument cart
3.1.8 Lightweight Portable Trolley
3.2 BACIS PARTS

4. OBJECTIVES OF STUDY……………………………………..…….12-13
4.1 ADVANTAGES OF PROJECT

5. METHODOLOGY……………………………………………….….14-15
5.1 BASICS CONCEPTS OF TROLLEY
5.2 EXISTING MODEL
5.2.1 Normal Motored Trolley
5.2.2 Tri Star Trolley
5.3 FACTOR CONSIDER WHILT DESIGNING

6. COMPONENT OF TROLLEY…………………………………..…..16-25
6.1 FRAME AND MATERIAL
6.2 MOTOR
6.2.1 Specification of Motor
6.3 BATTERY
6.3.1 Specification of Battery
6.4 CHARGER
6.4.1 Specification of Charger

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 6.5 WHEELS & TRI- STAR WHEEL
6.6 BALL BEARING
6.7 AXLE
6.8 SPEED CONTROL DEVICE
6.9 BELT

7. MODEL DISCRIPTION…………………………………………….26-33
7.1 ENGINEERING DRAWING OF TROLLEY
7.2 AUTOCAD 2D MODEL & DIMENSION
7.3 SOLID WORK 3D MODEL
7.3.1 Various Views of Trolley
7.4 3D VIEW
7.5 LAYOUT OF PROJECT

8. INSTRUMENT AND MACHINES………………………………..…34-38

8.1 MEASURING AND MARKING
8.1.1 Stainless Scale and steel Tape
8.1.2 Tri- Square
8.1.3 Scriber
8.2 GRINDING
8.3 WELDING
8.4 DRILLING
8.5 ASSEMBLING

9. FORCE ANALYSIS..............................................................................39-40
9.1 FORCE NECESSARY TO PULL THE TROLLEY
9.2 FORCE ANALYSIS ON WHEEL FRAME

10. MATHEMATICAL INTERPREATION …………………………..41-47

10.1CALCULATION OF DRIVE WHEEL TORQUE & MOTOR SELECTION
10.2LOAD CALCULATION FOR AXLE

11. WORK COMPLETED ……………………………..………………48-54

11.1 BASE FRAME
11.1.1 Mechanism Use In Base Frame
11.1.2 Mechanism Working In Base Frame
11.2 SIDE FRAME AND MECHANISM
11.3 MECHANISM IN FRAME

12. WORK TO DO……………………………………………………………55

13. COST ESTIMATION…………………………………………………….56
14. FUTURE LINKAGE ……………………………………………………..57
15. CONCLUSION…………………………………………………………....58
16. REFERENCE……………………………………………………………..59

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 LIST OF FIGURES
S. No TITLE PAGE NO.

1. Fig: 1.1 Trolley 3D View 1

2. Fig: 1.2 Importance of Project 3
3. Fig: 2.1 Normal Trolley 4
4. Fig: 2.2 Stair Climb Trolley 4
5. Fig: 3.1 Project Flow chart 5
6. Fig: 3.2 Traditional Shopping Trolley 6
7. Fig: 3.3 Rubbermaid Commercial Trolley 7
8. Fig: 3.4 Hospital Trolley 7
9. Fig: 3.5 Baby Trolley 8
10. Fig: 3.6 Multipurpose Trolley 8
11. Fig: 3.7 Stanchion Trolley 9
12. Fig: 3.8 Multi-functional Trolley 9
13. Fig: 3.9 Light Weight Trolley 10
14. Fig: 3.10 Trolley 11
15. Fig: 4.1 Objective of work 12
16. Fig: 4.2 Save Time 13
17. Fig: 4.3 Health Risk 13
18. Fig: 5.1 Motor Trolley 14
19. Fig: 5.2 Tri-Star Wheel 15
20. Fig: 6.1 Motor Trolley Frame 16
21. Fig: 6.2 Mild Steel Square Pipe 17
22. Fig: 6.3 Stain Less Butt Hinges 18
23. Fig: 6.4 Nuts & Bolts 18
24. Fig: 6.5 Motor 18
25. Fig: 6.6 Motor Dimension 19
26. Fig: 6.7 Battery 20
27. Fig: 6.8 Charger 21
28. Fig: 6.9 Wheel (Caster) 21
29. Fig: 6.10 Tri-Star Wheel 21
30. Fig: 6.11 Use of try star wheel on robot & 22
heavy vehicles with gear
31. Fig: 6.12 Mechanism of Try-star wheel 22
32. Fig: 6.13 Step of Stair climbing 23
33. Fig: 6.14 Ball Bearing 23
34. Fig: 6.15 How to use Chain & Bearing 23
35. Fig: 6.16 Axle 24
36. Fig: 6.17 DC Motor speed controller 24
37. Fig: 6.18 Belt 25
38. Fig: 7.1 Engineering Drawing of Trolley 26-27
39. Fig: 7.2 AutoCAD Model & Dimensions 28
40. Fig: 7.3 Front View 29

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41. Fig: 7.4 Top View 29
42. Fig: 7.5 Base Frame 30
43. Fig: 7.6 Side View 30
44. Fig: 7.7 3D Model on Solid Work 31
45. Fig: 7.8 Front View 31
46. Fig: 7.9 Side View 31
47. Fig: 7.10 Top View 32
48. Fig: 7.11 Trolley Cabin 32
49. Fig: 7.12 3D View 32
50. Fig: 7.13 Layout of Trolley 33
51. Fig: 8.1 Measurement Tools 34
52. Fig: 8.2 Tri-Square 35
23. Fig: 8.3 Scriber 35
54. Fig: 8.4 Grinding 35
55. Fig: 8.5 Cylindrical Grinding Machine 36
56. Fig: 8.6 Grinder Grinding Machine 36
57. Fig: 8.7 Grinding Wheel 36
58. Fig: 8.8 Cutting Blade 36
59. Fig: 8.9 MIG Welding Machine 37
60. Fig: 8.10 Welding on MIG 37
61. Fig: 8.11 Pillar Drilling Machine & Hand 37
Drilling Machine
62. Fig: 9.1 Maximum Load Determination 39
63. Fig: 9.2 Force Analysis on Wheel frame 40
64. Fig: 10.1 Load on Axle 45
65. Fig: 10.2 Bending Moment axis 46
66. Fig: 11.1 Frame 48-49
67. Fig: 11.2 Base Frame 49
68. Fig: 11.3 Stainless Steel Butts Hinges 50
69. Fig: 11.4 Base Frame Model 50
70. Fig: 11.5 Mechanism working on base frame 51
71. Fig: 11.6 Side Frame 52
72. Fig: 11.7 Mechanism of Folding 53-54

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 LIST OF TABLE

S. No. TITLE PAGE NO.

1. Table: 6.1 Specification of Motor 19

2. Table : 6.2 Specification of Battery 20
3. Table : 6.3 Specification of Speed controller 25
4. Table : 13.1 Cost Estimation 56

xii
 CHAPTER-1
INTRODUCTION

1.1 OVERVIEW
In everyday life, there will be many instances where heavy loads will have to be carried between
two locations, such as travel suitcase, books, etc. Moreover, in most of the buildings in the world
does not have elevators or escalators.
In this case human labors are considered to be the only solution. Labor is becoming costly as
well as time consuming in the developed countries. A motored 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.

Fig: 1.1 Trolley 3D View

This project aims to develop a simple mechanism to transport such weights with ease. Trolleys
helps to reduce the stresses a human being experiences while lifting loads from one place to
another over flat surfaces a staircase climbing trolley is developed which can carry heavy objects
up the stairs with comparatively less effort than to carry them manually When used properly,
trolleys can protect people from back injuries and other health problems that can result from
lifting heavy loads.
It is not difficult to observe that mechanical designs play an important role in assisting human
tasks. Stairs are one of the most commonly faced mobility challenges for robotic applications.
With the inspiration from the Industrial Center of the Hong Kong Polytechnic University, our
group has been involved in a project to design and develop a mechanical STAIR-CLIMBER that
can climb up and down the stairs in a stepwise and safe manner.

1
 After studying various options it was decided to build a trolley that could be carry load across
stair, also it was decided to power it manually so as to keep it in reach of many users. This
wilenable efficient handling of goods across stairs with less human energy.

1.2 AREA OF USE

1. Local society
2. Hospitals
3. Hotels
4. Malls
5. Small work area like construction.
6. Can be used by individuals for own purpose.
7. Airports and Railways station etc.
8. Houses (on stairs, rough surface etc.)

1.3 PROBLEM IDENTIFICATION

Most of the trolley available are not foldable and are not multifunctional and also they are not
motor operated and if it will be motor operated then it is only for plane surface not for stairs. To
fulfill the needs to transportation some carrying things are required for a short distance or stairs.
As per today's demands of the customer those carrying things should be able to carry enough
amounts of payload and in much less time. So our work aims on designing such trolley which
can carry goods in less time and require less effort for users.

1.4 EFFECT ON ENVIRONMENT

The effect of this project on environment is follows:

• Produce very less amount of noise
• Eco friendly in nature.
• The material which is use in it is biodegradable and recycle material is used.

1.5 SCOPE

Following scope of the project are as follow:

 Portable and easy for storage.
 Adjustable for variety of usage.
 Easy to operate.
 Reduce man power.
 Reduce labour cost.
 Reduce trolley cost.

1.6 NEEDS AND IMPORTANCE

The importance of this project is to make the life of the people more comfortable and luxuries.
This project is necessary for weak people who are not able to carry or push and pull the manual
trolley and it will also be used as a regular use while shopping and save a person to carry the

2
heavy good’s which save the with the various injuries such as (Muscle pull and strain, Sprained
ankle, Shoulder injuries, Knee injuries etc.). It is also important because it will carry more load
as compare to human. It reduces the effort of human and also it will work perfectly. It also help
to save the money which was given to others on Airports, Railway station and it may also use in
the industries and hospitals to reduce the human effort and also due to low maintenance it will
reduce the cost of carrying a goods from one place to another it may also say it’s a onetime
investment after that it’s a free.

Fig: 1.2 Importance of Project

It will reduce the time of transportation and also make easy to transport and this project also use
by the farmers to carry a load on a plane surface as well as on rough surface and this project is
the futures demanding project.

3
 CHAPTER-2
BACKGROUND OF TOPIC
After all the discussion about all the projects with all group members and coordinator,
conclusion was to make an AUTOMATIC TROLLEY. It was our coordinator idea and we
discussed about all the ideas to make it different, so we are now making a automatic trolley
which can easily walk on a plane surface by a D.C motor and easily climb the stair by the help of
caster wheels, and also our agenda was to reduce the trolley weight and make it compact and
easily foldable, ease assemble and dissemble. So we are making of combination of many
trolleys.

Most of the trolleys available are not foldable and not multi-functional
Most of the trolleys aren’t available for staircase
Trolley is equipment used to move heavy loads from one place to another. It can reduce the
human burden in their daily lives. This device is commonly used by a large number of industries
to transport physical products. Trolley is often used by those who organize and stock
merchandise in retail stores restock. When used properly, trolley can protect people from having
back injuries and other health problems that can result from lifting and carrying heavy loads.

Fig: 2.1 Normal trolley Fig: 2.2 Stair climb trolley

Most of the trolleys aren’t available for staircase. Stairs are one of the most commonly faced
mobility challenges for robotic applications. With the inspiration from the Industrial Center of
the Hong Kong Polytechnic University, our group has been involved in a project to design and
develop a mechanical STAIR-CLIMBER that can climb up and down the stairs in a stepwise and
safe manner.
After studying various options it was decided to build a trolley that could be carry load across
stair, also it was decided to power it manually so as to keep it in reach of many users. This will
enable efficient handling of goods across stairs with less human energy.

4
 CHAPTER-3
LITERATURE STUDY

The trolley is a mechanism that allowed man to transfer their heavy items such as computers,
files and etc to other places. It's help man to do their work without having a problem due to the
heavy loading. It’s also helps to reduce pain in waist, back, hand and feet. No matter how light
the loading is, people usually will suffocate a large pain in their body if lifting the items in many
times. So, this is when the people rely upon a trolley that can do items transferring many times
with just a little effort. From the statement above conclude that the trolley playing a major role as
an items transferring mechanism for people without having a problem of doing that. A trolley
also functioned as a helper to people to hold items orderly while transferring between rough
surfaces.

Fig: 3.1 Project Flow chart

5
The stair-climbing trolley is designed to reduce liability rather than increase it. Conventional
hand trucks work well on flat ground, but their usefulness decreases when it becomes necessary
to move an objecjt over an irregular surface. Package deliverymen, for example, often find it
necessary to drag loaded hand trucks up short flights of stairs just to reach the front door of a
building. The entire purpose of using a conventional Hand truck is tjo avoid having to lift and
carry heavy objects around. 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. We have done market survey to collect the information regarding the utility of this
.machine for Small scale industries and other cottage industries customers. Also we carried away
the market survey to see the raw material cost along with the finished product of the material
required to fabricate our unit. We referred Different books and journals along with the
periodicals, industrials magazines to collect the information.

3.1 TROLLEY TYPES, FUNCTIONS AND TECHINICAL REVIEW

3.1.1 Traditional Shopping Trolley

This type of trolleys is present on the malls, supermarkets and stores where always a fixed space
is there to store a trolley. These trolleys have Stable design; double ball bearing castor head
provides easy maneuverability, even when fully loaded and comes with a complete folding baby
seat as standard. All shopping trolleys come with option handle color, Red, Green, or Blue at no
additional cost.

Fig: 3.2 Traditional Shopping Trolley

3.1.2 Rubbermaid Commercial Cleaning Trolley

With innovative features for improved efficiency. In addition to three shelves for supplies, and
holders for mops, brooms and dust pan, the wire frame refuse bag holder has a cover with
storage compartment for small tools and supplies. Also features a polyliner support shelf/drip
pan. Uses replacement vinyl bag RCP 6183 YEL. Platform holds a 32-gallon container, standard-

6
size bucket or Micro fiber MopBuckets RCP Q950 and RCP Q900-88. Non marking 8" rear
wheels and 4" non marking casters. 21-3/4w x 46d x 38-3/8k

Fig: 3.3 Rubbermaid Commercial Cleaning Trolley

3.1.3 Hospital Trolley

Hospital trolley is the standard square metal trolley with casters on each leg to assist in quick
relocation of the trolley around the room or rooms. Hospital trolley is the most widely used item
of furniture in the hospital. There are different types of trolleys in a hospital to serve different
purposes. All trolleys come in different styles, sizes depending on the purpose it serves. For
example, there is mayo trolley to carry medical equipments or stretcher trolley to carry patients
or food trolley or cart trolley and so on.

Fig: 3.4 Hospital Trolley

3.1.4 Baby Trolley

The baby trolley is a mobile unit. It can be used under an infant radiant warmer or with stand
type photo therapy unit and can be used as a baby receivable trolley in the delivery room. The art
involves designing the unit for optimum functionality.

7
 Fig: 3.5 Baby Trolley

3.1.5 Multipurpose Trolley

Multipurpose trolleys made of stainless steel are available in two sizes. The multipurpose trolleys
can optionally be used as equipment, dressing and anesthesia trolleys, either with drawers and/or
ring for bowl or waste bag.

Fig: 3.6 Multipurpose Trolley

3.1.6 Stanchion Trolley

4 corner pockets for holding rungs or end panels. 2 swivel castors and 2 fixed castors, swivel
castors with wheel stops, solid rubber tyres, roller bearings. 1200 kg truck with fully elastic tyres
on aluminum rims. Ball bearings. Powder coated, light blue RAL 5012 as standard.

8
 Fig: 3.7 Stanchion Trolley

3.1.7 Multi-Functional Instrument Cart

The RiLab Instrument Cart is an excellent mobile workstation. Whether used as a mobile
laboratory or test stand, a computer support point or an assembly trolley, it provides a secure
location for the most sensitive equipment. It features four locking-place twin castors, an easy
transport handle, a six-plug power strip and a height adjustable utility shelf. Support columns
contain two vertical tapped strips for installation in 32 mm whole patterns. Numerous accessories
allow for customization of the cart according to specific needs. All shelves feature raised safety
edges and can support materials weighing up to 110 pounds.

Fig: 3.8 Multi-Functional Instrument Cart

3.1.8 Lightweight Portable Trolley

A platform on wheels for transporting wide and heavy items in workshop, office, warehouse and
etc.

9
 Fig: 3.9 Lightweight Portable Trolley

 HANDELING LARGE, BULKY OR AWKWARD ITEM:

The information searched on the handling large, bulky or awkward item give the information that
when implementing risk controls at your workplace, you must look at your hazards, assess the
risk, and determine whether the risk can be eliminated or reduced as far as reasonably
practicable. Your health and safety representatives (HSRs) and employees will often be the best
source of information and ideas on workplace design, layout, work methods and new technology
when looking at ways to manage risks arising from handling large, bulky or awkward items.
They will also be able to identify whether the proposed solutions will lead to the introduction of
other risks. You should also consider involving people such as designers, consultants, suppliers
and purchasing officers, particularly when looking at ways to influence what occurs in the supply
chain upstream and downstream of your workplace. The criteria for „large, bulky or awkward‟
items used in this Guide are items weighing 25kg or more and having one dimension 500mm or
more. However, you may find the principles in this Guide will help make your work safer, even
if the items you handle do not fit these criteria. In looking at ways to eliminate or reduce the risk
in consultation with your employees, you should consider the three elements below. Bear in
mind that these are not necessarily discrete steps, and that the most practicable method to control
risks in your situation may involve a combination of redesigning or repackaging, using
mechanical aids, and/or team lifts.

 STAIRCLIMBING TRANSPORTER:

The information searched on stair climbing transporter gives us the information that it is a
combination of rigid or restraining bodies so shaped and connected that they move upon each
other with definite relative motion. A machine is a collection of mechanisms which transmits
force from the source of power to the load to be overcome, and thus performs useful mechanical
work. Robotics is the area of automation which integrates the technology in variegated fields like
mechanisms, sensors & electronic control systems, artificial intelligence and embedded systems.
The synthesis of mechanisms is the very first step in any robot design depending upon its
application. These mechanisms are very costly so we make a very cheaper transporter.

10
 LIFTING AND HANDLING AIDS:

The information searched on Lifting and handling aids gives the information that how to
transport the load from one place to another. Frequent and heavy lifting and handling can cause
back injuries. But using lifting and handling aids can remove or reduce that risk and keep
workers healthy and at work. This guidance is intended for managers, employees and their
representatives and others involved in the selection of lifting and handling aids. In these
mechanism they made a simple trolley which help to transport the large load but it cannot help to
carry a load from stair so in our project made actually which help to carry a load from stair
easily. It makes very noise at working site these problem is solve in our project.

3.2 BASICS PARTS

 Body: For outdoor use such as warehouse or workshop that requires full strength of body,
wire frame or sheet metal body is used. Some trolley doesn't have any body on it on purpose,
and some using wood frame as the body.
 Handle: Usually all the trolley must have handled to provide less effort while using the
trolley due to heavy it's loading. But the design and the place of the handle are flexible and
differ from one another based on its center of force and design.
 Wheel: Usually made from rubber that joined together with the bolt and nut with steel frame
to ensure strength. Some trolley, food trolley for instance, only using wheels from wood
because don't require strength for the purpose.

Fig: 3.10 Trolley

11
 CHAPTER-4

OBJECTIVES OF STUDY

The main objectives of this project are to design and manufacture a trolley that has a lot of
function with extra features that can help people improve their daily life.

Its main objectives are:-

 Walk on plane surface easily with different-different speed.

 Lifting heavy objects especially where there are no lifting facilities.
 New option for transportation of loads over stairs which reduces man power.
 Easy to lift load over suitable height.
 Climb easily on stairs
 Easily foldable
 Easily assemble and dissemble
 Less weight

This project aims to develop a simple mechanism to transport such weights with easily. Trolleys
help to reduce the stresses a human being experiences while lifting loads from one place to
another over flat surfaces or on stairs.

Fig: 4.1 Objective of work

When used properly, trolleys can protect people from back injuries and other health problems
that can result from lifting heavy loads and also by minimizing the time period of carrying the
goods as compared to human powered trolley also reducing the problem of slipping and toppling
and attaining variable speed as per requirement of users and also make the life easy for small
level and also make the life more comfortable and luxuries.

12
4.1 ADVANTAGE OF PROJECT

There are various types of advantages are there and also in various fields where we have an
advantages of this project in which some advantages are discussed below:

• It reduces the human effort.

• It transports heavy luggage one place to another with ease.
• It minimizes the labour work.
• This trolley have caster wheel due to this it will carry a load on stairs also.
• Variable speed can be attained
• Rechargeable battery source
• Foldable
• Easily assemble and dissemble
• It minimizes time.

Fig: 4.2 Save time

• Trolleys helps to reduce the stresses a human being experiences while lifting loads from one
place to another over flat surfaces.
• When used properly, trolleys can protect people from back injuries and other health
problems that can result from lifting heavy loads.

Fig: 4.3 Health Risk

• It makes the life of the people easier and comfortable

13
 CHAPTER-5

METHODOLOGY

5.1 BASICS CONCEOTS OF TROLLEY

A trolley is moveable platform which is used for carrying the goods so a trolley must have
certain basic features for the transportation purpose like sufficient space for carrying goods, light
weighted, low cost, steering mechanism, front and back motion etc. The trolley should have a
good enough mechanism for pulling and pushing easily.

5.2 EXISTING MODEL

There are various existing models present in the market but they require manual power to pull or
push them and also many of them are having a motor option to move the trolley but it is also fail
when the rough surface or the stairs is there and also some trolley are only use for the stairs by
using tri star wheel.

5.2.1 Normal Motored Trolley

It should be motored operated trolley which reduces the effort of the users. If it is not operated
with motor it takes to much effort to move.

Fig: 5.1 Motor Trolley

Disadvantage

• Need more space to store

• Not adjustable
• Not be use as a personal at home
• Not climb Stairs
• Not be use as a travelling purpose
• Costly

14
5.2.2 Tri star Trolley

This is a trolley which is use only on stairs not for the surface and if it is not operated with motor
it will use on plane surface but take more effort.

Fig: 5.2 Tri-Star Wheels

Disadvantages

• Need more space to store

• Not adjustable
• Not be use as a personal at home
• Not be use as a travelling purpose
• Costly
• Not be used on plane surface if motored is used.

5.3 FACTOR CONSIDER WHILT DESIGNING

1. Age: 18 or above
2. Type of work to be performed: Transportation
3. Load needed to carry: Up to 80kg
4. Type of difficulties faced:

• Size of Trolley
• Frame hollow pipe diameter
• Adjustable
• Take less storage
• Easy to use
• Cost

5. Type of wheels to be used:

• Tri star wheel

• Casters or normal wheel

15
 CHAPTER-6

COMPONENTS OF TROLLEY

Following are the Components used in motor trolley are:

1. Frame and material
2. Motor (drive system)
3. Battery
4. Charger
5. Wheels and Tri star wheel
6. Ball Bearing
7. Axel
8. Speed control device
9. Belt

6.1 FRAME AND MATERIAL

Frame is main assembly of trolley mounted on axle .Aim to kept material that must be moved. A
frame is usually a structural system that supports different parts of a physical construction and/or
mild steel frame that limits the construction's extent. Framing, in construction, is the fitting
together of items to give a structure support and shape. Framing materials are usually wood, built
wood, or steel. Handle is to hold by mover and easy movement of trolley from one place to
different to hold heavy load trolley are a common form of transport in distribution environments,
for moving bulk loads. A very simple design offers a basic flat platform with two casters, two tri
star wheels and a fixed handle which is used to either push or pull the platform with the load on
the platform.

Fig: 6.1 Motor Trolley Frame

16
The axles are fixed the chassis, and the wheels are attached to the handle that allows the trolley
to be turned when moved. Basically if we are talking about trolley frame as shown in fig.6.1 it is
made up of mild steel square pipes of two different sizes of its diameter one is of 25.4 millimeter
and other one is of 12.7 millimeter as shown in fig: 6.2.
Mild steel (iron containing a small percentage of carbon, strong and tough but not readily
tempered), also known as plain-carbon steel and low-carbon steel, is now the most common form
of steel because its price is relatively low while it provides material properties that are acceptable
for many applications. Mild steel contains approximately 0.05–0.30% carbon making it
malleable and ductile. Mild steel has a relatively low tensile strength, but it is cheap and easy to
form; surface hardness can be increased through carburizing.
In applications where large cross-sections are used to minimize deflection, failure by yield is not
a risk so low-carbon steels are the best choice, for example as structural steel. The density of
mild steel is approximately 7.85 g/cm3 (7850 kg/m3 or 0.284 lb/in3) and the Young's modulus is
200 GPa .

Fig: 6.2 Mild steel square pipes

Low-carbon steels display yield-point run out where the material has two yield points. The first
yield point (or upper yield point) is higher than the second and the yield drops dramatically after
the upper yield point. If low-carbon steel is only stressed to some point between the upper and
lower yield point then the surface develops louder bands. Low-carbon steels contain less carbon
than other steels and are easier to cold-form, making them easier to handle. By these two pipes
we make the whole frame of the trolley. This material is used by us because it is cheaper and
having good strength and also easy to do various process for making trolley such as cutting,
welding, grinding etc. In the frame we also use four stainless steel butt hinges as shown in fig:
6.3 of size 152.4 millimeter to make the trolley lower portion movable and also use a two pieces
of stainless steel plates to holds the axels.
The frame of the trolley is joint with various nuts and bolts. It will be use to make the trolley
disassemble if no use of it’s which is easily disassemble and also easily assemble. The frame is
design in such a way that it will easily be assemble and disassemble and also easy to make
according to use it is adjustable and use as multipurpose such has it will be use while traveling,
housework, shopping etc. It is design such a way that it does not need more space to store.

17
 Fig: 6.3 Stainless steel butts hinges Fig: 6.4 Nuts and Bolts

6.2 MOTOR (DRIVE SYSTEM)

A DC motor is any of a class of rotary electrical motors that converts direct current electrical
energy into mechanical energy. The most common types rely on the forces produced by
magnetic fields.
This popular reduction dc motor is simply the most commonly used motor for Scooters, Bikes
and quad’s available in the market. Also due to its robustness it is also used in many DIY
projects making segway, e-cars and in many robotics like ATV robots and combat robots.

Fig: 6.5 Motor

In trolley we are using 24V DC motor of 250W having 300rpm (as per calculation). It will be
able to lift heavy load and move easily. By charging polarity we able to move our trolley in both
forward and backward direction easily.

18
 Fig: 6.6 Motor Dimensions
6.2.1 Specification of Motor

1. Voltage: 24 Volt DC.

2. Output: 250 Watt.
3. RPM (after Reduction) – 300.
4. Full load current – 13.4A.
5. No load Current – 2.2A.
6. Torque Constant – 8 N-m (80 kg-cm).
7. Torque stall – 40 N-m (400 kg-cm).
8. Sprocket 9Tooth only fits
9. For Chain Size: Pitch 0.5 inch.
10. Roller Diameter 0.3 inch.
11. Roller Width 0.16 inch.
12. Turn Potential 5V
13. Break Potential Low Potential Break
14. Adaption Motor 24V 250W
15. Ambient temperature -20o C to -45oC
16. Under voltage Protection 20.5V
17. Current limiting Protection 21.5A

Table: 6.1 Specification of Motor

6.3. BATTERY

A battery is a device consisting of one or more electrochemical cells with external connections
provided to power electrical devices such as electric cars. We are using battery of 24V which is
rechargeable. The battery will provide DC supply to motor by which motor will work.
Compatible with all kinds of mobiledevice power supply. The Smart Battery 24V 2200mah

19
Lithium Ion Battery features an automatic built in battery protection system (BPS) that makes
this battery plug and play for almost any application.

Fig: 6.7 Battery

6.3.1 Specification of Battery

1. Normal Voltage 25.6V

2. Charge Voltage 25.2V
3. Recommend Charging Current 2500mA
4. Maximum Safe Charging 7000mA
5. Capacity (amp hours) 25AH
6. Capacity (watts) 300W
7. Normal Discharge Current Upto 10A
8. Full Charge 40-90 minutes
9. Charge Cycle Upto 1000 Charge cycle
10. 30X Li-ion 3.7 V 2200mah cell(6S5P)
11. Range of Working 20V to 25.2V
12. BMS Cut off Approx 20V to prevent over discharge
13. Normal Discharge Current 10A
14. Peak Current 25A

Table: 6.2 Specification of Battery

6.4 CHARGER

A battery charger or recharger is a device used to put energy into a secondary cell or
rechargeable battery by forcing an electric current through it. The charging protocol (how much
voltage or current for how long, and what to do when charging is complete, for instance) depends
on the size and type of the battery being charged.

20
 Fig: 6.8 Charger

6.4.1 Charger specification

 This Charger is for Lithium Ion 24V battery.

 The charger is based on the modern high-frequency switching power supply structure,
built-in microcomputer control, to achieve fast, balanced, turbulent, floating charge
automatic control charging, charging speed, accurate and reliable.
 Current rating: 1.2A to 2A

6.5. WHEELS (CASTER) & TRI -STAR WHEEL

A wheel is a circular part that's meant to rotate on a shaft bearing. The wheel is one amongst the
key parts of the wheel and shaft that is one of the easy machines. Wheels, in conjunction with
axles, permit heavy objects to be moved simply facilitating movement or transportation whereas
supporting a load, or performing labour in machines. Wheels are also used for different purposes,
like a ship's wheel, hand wheel, wheel and flywheel.
Material: Polyurethane (PUR and PU)
It may be a compound composed of organic units joined by carbonate (urethane) links. Whereas
most polyurethanes area unit thermoses polymers that don't soften once heated, thermoplastic
polyurethanes also are on the market.

Fig: 6.9 Wheels (casters) Fig: 6.10 Tri-Star wheels

21
A Tri-Star wheel functions as a standard wheel on flat ground, however has the ability to climb
automatically once an impediment to rolling is encountered. This wheel design consists of three
tyres. They will conjointly allow a vehicle to climb over little obstructions like rocks, holes, and
stairs.

Fig: 6.11 Use of try star wheel on robot and heavy vehicles with gear

The third wheel idles at the top till the lower front wheel hits an obstruction. The obstruction
prevents the lower front wheel from moving forward however doesn't have an effect on the
motion of the live axle. This causes the top wheel to roll forward into position. If we are talking
about how to use try star-wheel on flat surface as well as on stairs then it’s a new concepts in our
project before that no one use this concepts on trolley this will use only on a small robot or in a
heavy vehicles as shown in fig 6.11.
It’s a first time to use try wheel with motor on both for stair as well as plane surface. We use two
try-star wheels on the lower section which is connected to each other with a shaft and the entire
tri wheel are in a contacted with each other with spear gear as shown in fig: 6.12.

Fig: 6.12 Mechanism of Try-Star wheel

When the shaft is rotated the all the wheels also star rotate. When the surface is plane then the
two wheel of tri star is on the surface but if any obstacles are their whole wheel is rotate and
cross the obstacles easily as shown in fig: 6.13.

22
 Fig: 6.13 Steps of Stair climbing

6.6 BALL BEARING

A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation
between the bearing races. 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 (e.g., a hub or shaft). 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 each other. Ball bearings tend to have lower load capacity for their
size than other kinds of rolling-element bearings due to the smaller contact area between the
balls and races. However, they can tolerate some misalignment of the inner and outer races.

Fig: 6.14 Ball bearing Fig: 6.15 How to use chain and bearing
Here we use a ball bearing in which Cain is used to rotate as shown in fig: 3.14. We fixed the
bearing on the axel to rotate the shaft the due to this the wheel is rotate. In this the two bearing is
used one at motor shaft and other on axel and both of them will attached to each other with
chain and when motor started then shaft will also rotated due to this trolley moves further as
shown in fig: 6.15.
We use the chain bearing in the trolley because the chain has various blocks due to which it has
no chance to slip on heavy load.

23
6.7 AXLE
An axle is a central shaft for a rotating wheel or gear. On wheeled vehicles, the axle is also
fastened to the wheels, rotating with them, or fixed to the trolley, with the wheels rotating around
the axle. In the several cases, bearings or bushings are provided at the mounting points wherever
the axle is supported.
We use a axel which is simply a rod and connected with the tri star wheel and the frame of the
trolley and this axel is also connect with motor with the help of chain and bearing due to this axle
Is rotate and then the wheel of tri star wheel start rotating. The length of axel is 711.2mm (28
inch) as shown in fig: 6.16.

Fig: 6.16 Axle

6.8 SPEED CONTROL DEVICE

The speed control of trolley will be the major issue at the work area as at different time
different speed will be required. So voltage regulator will help in controlling the speed by
changing voltage at the motors which will control motors rpm. A voltage regulator will help the
user to attain as much as speed required by him This Controller Includes a attachments for
motor, accelerator, brake, battery, battery charging, brake light, power lock. As shown in fig:
6.17

Fig: 6.17 DC motor speed controller

24
6.8.1 Specification of Speed controller

1. Voltage DC 24V

2. Under pressure 20V+ 1

3. Current Limit 21A + 1

4. Break Level High/ Low

5. Turn the Voltage 1.1-4.3V

6. Phase Angle 60/120

7. Power 250W

Table: 6.3 Specification of Speed Controller

6.9 BELT
Belt is used in our trolley to hold the goods or luggage in the trolley. It is fixed to trolley side
frame to make the luggage safe and it is adjustable according to the size of the bag or any
luggage and makes a people stress free. It is also remove from the trolley if it is not been used in
the trolley. This make the people free to care about the luggage which is hold in the trolley. We
use the normal belt made up of cloths to decrease the weight and cost. Belt is to be like as shown
in fig: 6.18.

Fig: 6.18 Belt

25
 CHAPTER-7
MODEL DISCRIPTION
We use ED Sheet, AutoCAD & solid work to for making the model as shown below. All the
measurement values are same as the trolley frame is ready no any change in the dimension of
frame.

7.1 ENGINEERING DRAWING

26
(b) (c)

(d)
Fig: 7.1 Engineering Drawing of Trolley

27
7.2 AUTOCAD 2D DRAWING & DIMENSION

Fig: 7.2 AutoCAD Model & Dimensions

28
Fig: 7.3 Front View

Fig: 7.4 Top View

29
Fig: 7.5 Base Frame

Fig: 7.6 Side View

30
7.3 SOLID WORK 3D MODEL

Fig: 7.7 3-D Model on solid work

7.3.1 Various Views of Trolley

Fig: 7.8 Front View Fig: 7.9 Side View

31
 Fig: 7.10 Top View Fig: 7.11 Trolley cabin

7.4 3D VIEW

Fig: 7.12 3D View

32
7.5 LAYOUT OF PROJECT

Fig: 7.13 Layout of Project

33
 CHAPTER-8
INSTRUMENT AND MACHINES
There is various method was use to make the frame of the trolley. This method was done
according to the 2-D and 3-D model of the frame. These operations will do by measuring the
length which was designed in auto-cad and solid work. These operations contain various
machines and various techniques. So we are telling about operation and machines are as follows:

8.1 Measuring and Marking

It is an operation in which we measure the things according to our use and then mark on the
surface of the material or work piece. We use some instrument to complete the operation which
is shown below:

8.1.1 Stainless Scale and Steel Tape

A scale in graphs can be defined as the system of marks at fixed intervals, which define the
relation between the units being used and their representation on the graph. Here, for instance,
the scale of the graph is 1 interval being equal to 10 units.
We use this to measure the pipes according to our use for further process.

a. Stainless Scale b. Stainless Steel Tape

Fig: 8.1 Measuring tools

8.1.2 Tri-Square

A try- square is a woodworking tool used for marking and measuring a square piece of wood. The square
refers to the tool's primary use of measuring the accuracy of a right angle (90 degree angle); to try a
surface is to check its straightness or correspondence to an adjoining surface.
We use this instrument to check the cutting and grinding surface of the pipes and also use to
check the angle between the joints.

34
 Fig: 8.2 Tri- Sqare

8.1.3 Scriber

A scriber is a hand tool used in metal work to mark lines on work pieces, prior to machining. The
process of using a scriber is called scribing and is just part of the process of marking out.
This tool is used by us to mark on the surface to confirm the operation accuracy which is done
further. This tool is also called Marking tool.

Fig: 8.3 Scriber

8.2 Grinding

Fig: 8.4 Grinding

35
Grinding is an abrasive machining process that uses a tool made up of abrasive powder. Main
Aim of grinding process is not to remove material; but to achieve or control dimensions within
close tolerance; or to achieve good surface finish which is otherwise difficult to achieve by
traditional material removal processes.
We use this operation with the help of grinding machine. We use this operation to cut the pipes
and also cleaning the surface of the pipes with the help of cutting blades and grinding wheel as
shown in fig: 8.5.

Fig: 8.5 Cylindrical Grinding machine Fig: 8.6 Grinder Grinding Machine

Cylindrical Grinding machine help us to remove the extra material on the workpiece but Grinder
Grinding Machine is use for two operation one is for cutting and grinding for both the process
the different wheel and blades are use as shown in fig: 8.7 and fig: 8.8.

Fig: 8.7 Grinding Wheel Fig: 8.8 Cutting Blade

36
8.3 Welding

Welding is the process of joining two plastic or metal parts by melting them, with or without
using a further molten material. The heat produced by an arc is used in welding to melt metal
rods, which solidify to provide a strong joint between two metal surfaces.

Fig: 8.9 MIG Welding Machine Fig: 8.10 Welding on MIG

We use this process to join the square pipes according to our use. We use MIG welding machine
MIG stand for Metal Inert Gas. We use MIG because it will take less time.

8.4 Drilling

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit is pressed
against the work-piece and rotated at rates from hundreds to thousands of revolutions per minute.

Fig: 8.11 Pillar Drilling machine and Hand Drilling Machine

37
This operation use to drill on the frame of 5mm to tight the nuts and bolts. This will help us to
make the trolley adjustable i.e. assembled and disassembled. Machine used for drilling on the
frame are shown in fig: 8.11.This both the machine is used by use on the frame according to use
but the maximum machine used by us is Pillar Drilling Machine due to easy use and also take
lesser time.

8.5 Assembling

Assembling is the process of putting all the parts together to make a machine or other product.
So, after fabrication many components of the trolley by raw stock material and turning it into a
parts, Here comes assembling in which we assemble all the components together and make a
working trolley from fabrication components.

38
 CHAPTER-9
FORCE ANALYSIS
9.1 FORCE NECESSARY TO PULL TROLLEY

Fig: 9.1 Maximum Load Determinations

F. X= W. Y

F=W*Y
X
Values are taken:
W= 600N Y= 0.56m X= 0.80m

F = 600 X 0.56/0.80

F= 420N

9.2 FORCE ANALYSIS ON WHEEL FRAME

Assume that

 W1= weight of object to be carried

 W2= weight of the trolley

39
 Re = reaction force on one side
 F = force applied (on one lever)
 Ro = distance of centroid from center of wheel
 K = distance between center of wheel and line of action of weight

Fig: 9.2 Force Analyses on Wheel Frame

(W1 + W2 - F Sin θ) k = F Cos θ (R2 - k2)1/2

2
Re Cos φ = F Cos θ

Re Sin φ + F Sin θ = (W1 + W2)

2
Re = ((F Cos θ) + (W1 + W2 - F Sin θ)2 )1\2
2

2
Tan φ = W1 + W2 – 2 F sin θ
2Fcosθ

40
 CHAPTER-10
MATHEMATICAL INTERPRETATION
10.1 CALCULATION OF DRIVE WHEEL TORQUE & MOTOR SELECTION CRITERIA

For selecting motor for drive wheel, a number of parameters must be considered, to calculate the
maximum required torque. The calculation will be for load condition, i.e. when there is weight
on the trolley.

Specifications for the trolley:

Load applied/ carried = 50 kg (distributed equally to the base and axle)

Weigh of the trolley = 10kg (uniformly distributed throughout the axle)

So,

Load of the trolley = 10kg (Assume) (f =ma)

= 10*9.81
= 98.1N

Load to be carried = 50kg

= 50*9.81
= 490.5 N

Gross weight G.W = 10 +50

= 60 kg = 60*9.81 = 600 N (approx.)

Wheel radius (r) = 10 cm = 0.1 m

Max speed (v) =5kmph = 1.4m/s

Let the max inclination of surface on which trolley moves will be 3° (in worst case)When trolley
or vehicle will be running on ground

 So, inclination angle α = 3°

Time to attain top speed can be taken as 5 sec
So, time required to attain, ta = 5 sec (Top speed)
Considering the surface for normal condition as concrete of good or fair type.
For selecting motors that can produce torque of required quantity, it is important to calculate
total tractive effort (TTE), required by the trolley in moving condition.
Total Tractive Effort (TTE) is the sum of various quantities.
TTE (in kg) = RR (in N) +GR (in N) + FA (in N)
Where,

41
TT = Total Tractive Effort (N).
RR = force required to overcome Rolling Resistance (N).
GR = Gradient Resistance (N), i.e. force required to overcome inclination.
FA = Force required to accelerate trolley to top speed (N).

 Total Tractive Effort = Rolling Resistance + Acceleration+ Force + Gradient

Resistance
Rolling Resistance (RR)

It is force required in kg to overcome friction from ground and to move on any surface.

Rolling resistance = gross weight *µ (µ = coefficient of rolling friction)

 (For rubber wheel)µ= 0.007 to 0.02

 (Nylon wheel)µ= 0.03
 (Polyurethane wheel)µ =0.05
So,

(For rubber wheel and concrete surface)µ= 0.012

Rolling resistance = G.W *µ

=600*0.012

= 7.2 N

Acceleration force (F)

This is the force required to accelerate the trolley to the top speed in certain time interval.

Acceleration force = m * a

= m *(v-0)/taor G.W*-(v-0)/ta*9.81

Assuming time for according to obtain max speed is 5 sec

F= 600*1.4/5*9.81

= 17.12N

Gradient resistance (G.R)

Grade resistance is the force required to move the trolley up the slope or inclination.

Gradient resistance = gross weight * sin α°

42
 = 600 * sin 3°

= 31.40N

Total tractive effort (TTE)

Total Tractive Effort = Rolling Resistance + Acceleration+ Force + Gradient Resistance

Total tractive effort (TTE) = RR +F +G.R

= 7.2+17.12+31.40

= 55.72N

Now,

For verifying that the drive wheel will move or not, it is required to calculate drive wheel torque,
T

Driving Torque (T)

Driving Torque (T)= TTE * r * RF

r = radius of wheel

RF = resistance factor (frictional losses between the axle and wheel)

It is generally 1.1 to 1.5

RF =1.5

Driving Torque (T) = 55.72 * 0.1 *1.5

=8.358 N- m

Rotational speed (N) RPM

Angular velocity ɷ = linear velocity/ radius

ɷ= 1.4/0.1 = 14 rad/sec

ɷ= 2πN/60 = N= 14*60/2π

N = 134rpm

43
Power Calculation

Power = 2πNT/60

=2π*134*8.359/60

= 117.283 W

 Fairly assume the motor& gears assembly is 80% efficient

Actual power of motor pumps in the form

Therefore,

Source would be = 117.283/0.8 = 147W

In case of climbing of stairs:-

Power = force * velocity (Velocity = displacement/ time)

= 600 * 1.4/5 = (v-o)/t

= 168 W

 Fairly assume the motor& gears assembly is 80% efficient

Actual power of motor pumps in the form

Therefore,

Actual Source would be = 168/0.8

= 210W

So,

Power should be 210 W or more to run this trolley on surface and stairs

So,

The final torque will be

P = 2πNT/60

T= 210 *60/2π*134

T= 15 N-m

So, required torque will be transmitted to the ground and there will be no occurrence of slipping.

44
Motor Selection Criteria

By above calculations of torque required and power, the required motor can be selected.
The dc motor will be best suited for the above design.

Specifications of selected dc motors

24V 250W 300RPM DC Geared Motor

 Voltage: 24 Volt DC
 Output: 250 Watt
 Adaption motor: 24V 250W
 Ambient temperature: -20°C -- 45°C
 Turn potential: 5V
 Brake potential: Low potential brake
 RPM (after Reduction) – 300
 Full load current – 13.4A
 No load Current – 2.2A
 Under voltage protection: 20.5V
 Current Limiting protection: 21.5A
 Torque Constant – 8 N-m (80 kg-cm)
 Torque stall – 40 N-m (400 kg-cm)
 Sprocket: 9Tooth only fits #410 bicycle chains
 For Chain Size: Pitch 0.5 inch
 Roller Diameter 0.3 inch
 Roller Width 0.16 inch

10.2 Load and Calculation for Axle

Fig 10.1 Load on axle

Length of the axle= 635 mm

Load applied/ Carried = 50 kg (Distributed equally by the welds to the axle)

= 490 N

45
Weight of the trolley = 10kg (uniformly distributed throughout the axle)

= 98 N
Total load = load applied (load carried) + weight of trolley
= 490 + 98
= 588 N

Neglecting the overhang beyond welded points since the wheel provides only negligible reaction

From equilibrium equation ∑F=0

and ∑M = 0

Find the reaction at the supports.

RA = 294 N

RB = 294 N

Calculate the maximum bending moment for the beam,

Fig : 10.2 Bending moment axis

M = 294 X 330.2 – 294 (330.2-50.8)

M =14.94 N-m

Considering factor of safety

(FOS) = 1.5

Maximum bending moment (Mmax) = 22.41 N-m

46
Bending Equation,

M=σ=E
I y R
Substituting the values of maximum bending moment (M max) = 16.80 N-m

I = π r4 / 4

= π (0.02)4 = 1.25 X 10-07 m4

4

Y = 0.660 = 0.33m
2

σ= MY = 22.41 X 0.33
I 1.25 X 10-07

= 5.91 X 107 N/m2

σ = 59.1 N/mm2

Bending stress for the given material can be assumed to be 0.66 * yield strength

Thus, the allowable bending stress for the given material is 200 N/ mm2 .

The calculated bending stress for the material is within the allowable bending stress for the
material,

Thus the design is safe

47
 CHAPTER-11

WORK COMPLETED
Our 70 percent work is done. We use various mechanisms to make the trolley more reliable. In
30 percent work only assembling and extended trolley handle is left and other works are
completed that is the work of the frame in which we have to do various operations such as
Grinding, Welding and Drilling etc. axle work, 3-D model of trolley on Solid-Work. Now we
have to just make it automatic by using motor and battery and few mechanisms. A frame is
shown in fig: 11.1.

(a)

(b)

48
 (c)

Fig: 11.1 Frame

11.1 BASE FRAME

The base frame is prepared with help of cutting of pipes with grinding machine and welding
process as shown in fig: 11.2.

Fig: 11.2 Base Frame

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11.1.1 Mechanism use in base frame

We use the four stainless steel butts hinges (fig: 11.3) which is attached with the trolley frame.
This hinges are fixed on the frame with the help of nuts and bolts shown if fig: 11.4.

Fig: 11.3 Stainless Steel butts hinges

Fig: 11.4 Base Frames Model

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11.1.2 Mechanisim working in base Frame
We use a simple Mechanism in a base to fold and open that is the door stainless steel it is also be
removable if we want to disacemble.It should be fixed with the help of nuts and bolts. This help
to place the trolley in a very small place.The Mechanism shown in fig: 11.5.

Fig: 11.5 Mechanism working on base frame

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11.2 SIDE FRAME AND MECHANISM

This frame is removable according to use so we use four nuts and two thin rods to make it. This
is Easy to remove and also easy to put again shown in fig: 10.6.

(A) (B) (C)

(D) (E)
Fig: 11.6 Side Frame

In fig: 10.6 (E) we use a rectangular plate which is fixed with two bolts and nut to make the side
frame move and fold from two places according to use. We also completed the work of the
trolley Axle.

11.3 MECHANISM IN FRAME

In this we weld the two nuts on both side of the frame and cut side portion of the the nut of uper
side and in a side frame we weld the thin rod which is easly go inside the nut and aslo the rod
will weld on the frame with the help of thin rectangular chip size plate and by this we adjest the

52
frame easly and also it is easy to remove if no needs. Mechanism work is shown in fig: 10.7. It
shows how the side frame close easly.

(a) (b)

(c) (d)

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(e) (f)
Fig: 11.7 Mechanism of folding

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 CHAPTER- 12

WORK TO DO

• Work on Extension of handle of base and main frame of the trolley.

• Purchasing
 DC Motor
 Wheels and Tri star wheels
 Speed controller
 Gears
 Chain
 Switch board
 Battery and wires
• Work on Axle
• Assembly
• Testing

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 CHAPTER- 13

COST ESTIMATION

Table:13.1 Cost Estimation

56
 CHAPTER- 14

FUTURE LINKAGE

• Internal breaking system may be used as effective breaking system.

• A Throttle acceleration may be used for effective acceleration.
• This trolley is operated by hand which may be operated by motor so as to reduce human
effort.
• May be used in industries for caring load from one place to other place
• It has a big advantage of caster wheel by which it can climb on stairs to so easily carry load
from one place to other.
• May be it could be used for domestic purposes because it’s easily foldable and easily
assemble and dissemble
• It may be use in railways and airports to carry heavy luggage’s.
• It could be use in colleges to carry college heavy loads
• It could be use in colleges in future to maximize its efficiency and make it more efficient
with new mechanisms and techniques.
• In future it could be a smart trolley
• In significant construction projects, there's currently a choice of special ways and equipment
of materials handling.

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 CHAPTER -15

CONCLUSION

Though this project had some limitation as a first step of making any Stair Climbing trolley, it
was an experimental project. In all both rolling and climbing modes gives a new transportation
mode over stairs and rough surfaces with maximum inclination angle 44 degree. The main aim of
this project is easy handling, stairs climbing mechanism for load carrier with lesser efforts. With
conclusion of all papers, we have an idea of materials, specification of bearings and wheels. With
this we try include one another modification in our trolley we make it easy to assembling and de
assembly and we make the trolley in two types so either you can use it as trolley bag type or
luggage type. Though this project had some limitations regarding the strength and built of the
structure, it can be considered to be a small step forward, as far as Stair 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 loads up the stairs. This product will be well acclaimed if
it can be commercialized to suit the needs. Though the initial cost of the project seemed to be
higher but more accurate manufacturing would shorten this. As far the commercial aspects of
this product are concerned, if this product can be fully automated and produced at a lower cost
the acceptance will be unimaginable. Presently, there are no competitors for such a kind of
product in our market.

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 CHAPTER-16

REFERENCE

• Leppänen, S. Salmi, Halme, A., 1998, “WorkPartner HUT Automation’s new hybrid
walking machine”, CLAWAR’98 First international symposium, Brussels.
• IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-
1684,pISSN: 2320-334X, Volume 12, Issue 3 Ver. II (May - Jun. 2015), PP 72-84
www.iosrjournals.org DOI: 10.9790/1684-12327284 www.iosrjournals.org 72 | Page (
Fabrication of Automated Electronic Trolley)
• Dr.R.K.Bansal, A text book of Strength of materials, Laxmi Publications(P) Ltd.
• Mr. Pratik H. Rathod , Mr. Ravi R. Mishra , Mr. Nitin A. Waghamare ,design and
fabrication of stair climbing hand truck, international Journal of Emerging Trends in
Engineering and Development, Issue 3, Vol.5, September, 2013.
• • B.RAVINDAR, M.KIRAN KUMAR, K.RAJASHEKAR, G.RAJKUMAR Mechanical
Engineering Department, Vaageswari College of Engineering, Karimnagar, Telangana,
India(2018) Project report
• Ansh Mahil (111ID0573) Dheerendra Singh Rajput (111ID0473) Department of Industrial
Design National Institute of Technology, Rourkela Rourkela, Odisha – 769008 2011-15
project report
• NUR ADILAH BINTI AHMAD Report submitted in partial fulfilment of the requirements
for the award of Diploma in Mechanical Engineering Faculty of Mechanical Engineering
UNIVERSITI MALAYSIA PAHANG 2008
• SUNIL KUMAR K R (310111114091),SUNITHA V S (310111114092) SURESH K
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Tex Tembi (3320703) Mahreen Riaz (3327322) Mingzhi Sun (3325220) Hugo Fernando
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• Automotive Engineering Book By G.B.S. Narang Khanna Publishers (1 January 1995) 5 th
Edition.
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www.robokits.co.in
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www.amazon.in

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