DESIGN AND FABRICATION OF STAIR CLIMBER TROLLEY A PROJECT REPORT PDF

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DESIGN AND FABRICATION OF STAIR CLIMBER TROLLEY A PROJECT REPORT Submitted by SUNIL KUMAR K R 310111114091 SUNITHA V S 310111114092 SURESH K 310111114094 UDAYA KUMAR S 310111114098 in partial fulfillment for the award of the degree Of BACHELOR OF ENGINEERING in MECHANICAL ENGINEERING ANAND INSTITUTE...

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DESIGN AND FABRICATION OF STAIR CLIMBER TROLLEY A PROJECT REPORT Submitted by

SUNIL KUMAR K R

310111114091

SUNITHA V S

310111114092

SURESH K

310111114094

UDAYA KUMAR S

310111114098

in partial fulfillment for the award of the degree Of

BACHELOR OF ENGINEERING in MECHANICAL ENGINEERING

ANAND INSTITUTE OF HIGHER TECHNOLOGY CHENNAI-603 103

ANNA UNIVERSITY :: CHENNAI-600 025 APRIL 2014

i

Abstract This project aims at developing a mechanism for easy transportation of 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 endeavors to study the commercial viability and importance of such a product. 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 irregular surfaces like holes, bumps, etc.

ii

TABLE OF CONTENTS

CHAPTER NO

1.

PAGENO

ABSTRACT

ii

LIST OF TABLES

vii

LIST OF FIGURES

viii

LIST OF SYMBOLS

ix

INTRODUCTION

1

1.1

HAND TROLLEY

1

1.1.2 DESCRIPTION

1

TYPES OF TROLLLEY

2

1.2.1 WHEELED TROLLEY

2

1.2.2 FOLDING TROLLEY

2

1.2.3 GARDEN TROLLEY

3

1.2.4 KITCHEN TROLLEY

3

1.2.5 STACK TROLLEY

3

1.2

2

TITLE

1.3 NEED FOR STAIRCLIMBER TROLLEY

3

STAIR CLIMBER TROLLEY

4

2.1

4

NEW CONCEPT

iii

3.

TRI-STAR WHEEL

5

3.1

TRI-STAR WHEEL DESIGN

5

3.2

APPLICATION OF TRI-STAR WHEEL IN OUR PROJECT

4.

6

SELECTION AND FABRICATION OF STAIR CLIMBER TROLLEY

7

4.1

7

MATERIAL SELECTION 4.1.1 TROLLEY BODY

7

4.1.2 TRI-STAR WHEEL WEB

7

4.2

BEARING SELECTION

8

4.3

WHEEL SELECTION

9

4.3.1 TYPES OF WHEEL MATERIAL

9

4.3.1.1 FILLED RUBBER

9

4.3.1.2 POLYURETHANE

9

4.3.1.3 STEEL

10

4.3.2 STATIC FRICTION

10

4.3.3 VARIOUS WHEEL MATERIALS

iv

AND CO-EFFICIENT OF FRICTION 4.4

WHEEL FRAME

10 11

4.4.1 TYPES OF WHEEL FRAMES

12

4.5 CAD MODEL OF TROLLEY

13

4.6 PROCESS INVOLVED IN FABRICATION

14

4.6.1 GAS CUTTING

14

4.6.2 PIPE BENDING

15

4.6.3 PLASMA ARC CUTTING

15

4.6.3.1 COMPONENTS OF THE SYSTEM

16

4.6.3.2 PROBLEMS FACED BY THE EQUIPMENTS 4.6.4 WELDING 4.6.4.1 ARC WELDING

5.

17 17 18

4.7 PROTOTYPE OF STAIR CLIMBER TROLLEY

19

DESIGN ANALYSIS OF TROLLEY

20

5.1 LOAD CALCULATION FOR AXLE

20

5.2 FORCE NECESSARY TO PULL THE TROLLEY

22 v

5.3 FORCE ANALYSIS ON WHEEL FRAME

23

6.

COST ESTIMATION OF THE PROJECT

25

7.

DISCUSSION AND CONCLUSION

26

7.1 INFERENCE

26

7.2 CONCLUSION

27

REFERENCES

28

LIST OF TABLES vi

TABLE NO.

4.1

6.1

TABLE

PAGE NO.

Various wheel materials and co-efficient of friction

10

Account statement

25

vii

LIST OF FIGURES

FIGURE NO.

FIGURE

PAGE NO.

3.1

Tri-Star wheel in motion

5

4.1

Close-up showing surface roughness

10

4.2

Co-efficient of kinetic friction of various tyre materials and surface

11

4.3

Straight Wheel Frame

12

4.4

Curved Wheel Frame

12

4.5

Quasi-Planetary Wheel Frame

13

4.6

CAD model of trolley Side View

13

4.7

CAD model of trolley Front View

13

4.8

CAD model of trolley Isometric View

14

4.9

Plasma Arc Cut Tri-Star Wheel Web

16

4.10

Prototype of Stair Climber Trolley Side View

19

4.11

Prototype of Stair Climber Trolley Front View

19

7.1

Modified Wheel Frame Setup

26

viii

LIST OF SYMBOLS

SYMBOL

DEFINITION

F

Force

M

Bending Moment

R1, R2

Reaction Forces

I

Moment of inertia Bending Stress

y

Distance between neutral axis and centroidal axis

E

Young’s Modulus

R

Radius of Curvature

x

Height of the trolley

y

Distance between mid-point of the weight 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

ix

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Chapter 1 INTRODUCTION 1.1 HAND TROLLEY 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 A typical hand trolley consists of two small wheels located beneath a load-bearing platform, the hand trolley usually has two handles on its support frame. These handles are used to push, pull and maneuver the device. The handles may extend from the top rear of the frame, or one handle may curve from the back. An empty hand trolley usually stands upright in an L-shape, and products are usually stacked on top of the platform. When the goods are in place, it is tilted backward so that the load is balanced between the platform and the support frame. Especially if heavy or fragile materials are moved, the person operating the trolley should return it to an upright position carefully, to insure nothing falls off the platform. The front of the frame may be squared off for boxes or curved for drums and barrels. Sometimes, a hand truck also has straps for securing loose freight during transport. Professional material handlers prefer to use a hand truck when moving stackable items such as boxes, crates or packages. Heavier items are usually stacked on the bottom of the hand truck, with lighter objects saved for the top.

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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. 1.2 TYPES OF TROLLEY 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, aluminium 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 large products. 1.2.1 Wheeled trolley 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 lighter materials. 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. 1.2.2 Folding Trolley A folding trolley is another type of hand tool, and is often made of rustproof aluminium. 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-

1.2.3 Garden Trolley The garden trolley is a maneuverer with the use of a pull handle. Garden trolleys tend to have narrow profiles so that they will fit easily on paths and walks without damaging plants. These are designed so that they are capable of lifting both dry and marshy loads which are most commonly found in gardens. 1.2.4 Kitchen Trolley 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. 1.2.5 Sack Trolley Sack trolley or Sack barrow is a fairly generic term describing a range of light, single operator hand trucks or trolleys used to move cartons, feed and grain sacks, and other light, stackable goods. Lots of different materials are used to make sack trucks. This includes high impact plastics, tube steel, aluminium steel, and aluminium excursion. 1.3 NEED FOR STAIR CLIMBER TROLLEY Lifting heavy objects to upper stories or lifting patients to upper levels from the ground are not painless jobs, especially where there are no lifting facilities (elevator, conveyer, etc.).

Moreover, most of the buildings are

structurally congested and do not have elevators or escalators. This project can introduce a new option for the transportation of loads over the stairs. The stair climbing hand trolley can play an important role in those areas to lift loads over a short height.

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CHAPTER 2 STAIR CLIMBER TROLLEY 2.1 NEW CONCEPT The stair-climbing hand truck 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 object 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 to 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. 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.

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CHAPTER 3 TRI-STAR WHEEL 3.1 TRI-STAR WHEEL DESIGN 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 Terrastar, 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 figure 3.1.

Fig3.1 Tri-Star wheel in motion -5-

3.2 APPLICATION OF TRI-STAR WHEEL IN OUR PROJECT In our project, we are using this Tri-Star wheel arrangement in a hand trolley in the place of normal wheels setup to enable the trolley to climb up and down the stair cases and also to up come small obstacles like holes and bumps on its path.

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CHAPTER 4 SELECTION AND FABRICATION OF STAIR CLIMBER TROLLEY 4.1 MATERIAL SELECTION Material selection is a step in the process of designing any physical object. In the context of product design, the main goal of material selection is to minimize cost while meeting product performance goals. Systematic selection of the best material for a given application begins with properties and costs of candidate materials. 4.1.1 Trolley body Material Used- Mild Steel Mild Steel 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 (30,000,000 psi). 4.1.2 Tri-Star wheel web Material Used- Stainless Steel Grade 304 Stainless Steel Grade 304: 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 -7-

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 Type 304. 4.2 BEARING SELECTION 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 each other. 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

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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.

4.3 WHEEL SELECTION

Wheel material selected – Filled rubber

4.3.1 Types of Wheel Material 4.3.1.1 Filled rubbers 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 marketing positions. 4.3.1.2 Polyurethane Polyurethane (PUR and PU)

is

a polymer composed

of

a

chain

of organic units joined by carbamate (urethane) links. While most polyurethanes are thermosetting polymers that do not melt when heated, thermoplastic polyurethanes are also available. The main ingredients to make a polyurethane are isocyanates and polyols. Other materials are added to help processing the polymer or to change the properties of the polymer. -9-

4.3.1.3 Steel 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. 4.3.2 Static friction The surface of the wheel and what it is rolling on are not perfectly smooth. They have irregularities shown in figure 4.1.

Fig4.1 Close-up showing surface roughness In sliding friction, this surface roughness is the reason for the static and kinetic resistance to motion. Although the wheel is not sliding, the ...