5/17/2017

AME: 5001
International Mechanical
Engineers Challenge

Module Tutor: Shimna Shafeeq

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Table of Contents
1. AIMS & OBJECTIVE ........................................................................................................................... 3
2. HEALTH & SAFETY ............................................................................................................................. 3
3. INTRODUCTION ................................................................................................................................ 3
4. DESIGN SELECTION ........................................................................................................................... 4
5. STAIR CLIMBING ROBOT .................................................................................................................. 5
6. LITERATURE REVIEW ........................................................................................................................ 6
6.1. Battery........................................................................................................................................... 6
6.2. Motors........................................................................................................................................... 7
6.3. Wheels .......................................................................................................................................... 7
6.4. Rod ................................................................................................................................................ 8
6.5. Base ............................................................................................................................................... 8
6.6. Shaft .............................................................................................................................................. 9
7. 3D & 2D DESIGN ............................................................................................................................. 10
7.1. 3D Modeling Design .................................................................................................................... 10
7.2. 2D Modeling Design .................................................................................................................... 14
8. MANUFACTURING PROCESS .......................................................................................................... 15
9. PROBLEM FACED ............................................................................................................................ 17
10. PRODUCT PRICE .......................................................................................................................... 18
10.1. Materials Invoice ..................................................................................................................... 18
11. TESTING ...................................................................................................................................... 18
12. COMPETETION ............................................................................................................................ 19
13. PROJECT PLANNING ................................................................................................................... 20
14. FURTHER IMPROVEMENT .......................................................................................................... 20
15. CONCLUSION .............................................................................................................................. 21
16. REFERENCE.................................................................................................................................. 22

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List of Figure
Figure 1: Stair Climb Robot (Google Image) 2017 ...................................................................................... 4
Figure 2: Stair Climbing Wheel Chair (Google Image) 2017 ....................................................................... 6
Figure 3: 12V Battery (Self-Capture) 2017 ................................................................................................. 7
Figure 4: 12V Motor (Self-Capture) 2017................................................................................................... 7
Figure 5: Wood Wheel (Self-Capture) 2017 ............................................................................................... 8
Figure 6: Rod (Self-Capture) 2017 .............................................................................................................. 8
Figure 7: Base (Self-Capture) 2017 ............................................................................................................... 9
Figure 8: Shaft (Google Image) 2017.......................................................................................................... 9
Figure 9: Battery (Solid-Works) 2017 ....................................................................................................... 10
Figure 10: Motor (Solid-Works) 2017 ...................................................................................................... 10
Figure 11: Shaft (Solid-Works) 2017 ........................................................................................................ 11
Figure 12: Front View (Solid-Works) 2017 ............................................................................................... 11
Figure 13: Top View (Solid-Works) 2017 .................................................................................................. 12
Figure 14: Side View (Solid-Works) 2017 ................................................................................................. 12
Figure 15: Front View (Solid-Works) 2017 ............................................................................................... 13
Figure 16: Half View (Solid-Works) 2017 ................................................................................................. 13
Figure 17: 2D Design (Solid Works) 2017 ................................................................................................. 14
Figure 18: Wood for Base (Self-Capture) - 2017 ......................................................................................... 15
Figure 19: Wheel (Self-Capture) - 2017 ...................................................................................................... 15
Figure 20: Fixing the project (Self-Capture) 2017 ....................................................................................... 16
Figure 21: Motors (Self-Capture) - 2017 ..................................................................................................... 16
Figure 22: Fitting Battery (Self-Capture) - 2017 .......................................................................................... 17
Figure 23: Project Planning Schedule (Excel) - 2017 ................................................................................... 20

List of Table
Table 1: Invoice - 2017 ................................................................................................................................ 18

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1. AIMS & OBJECTIVE

In this task we have to design and manufacture parts required to make the system
perform at its optimum. In addition, this project includes designing and building the
equipment needed to manufacture the unit and function correctly.

2. HEALTH & SAFETY

The project which builds by our group was made up of wood. We used Furniture wood
and Thermocoil. It may cause serious damage on hand while cutting.

Some rules to follow in lab:

Wear safety shoes

Wear hand gloves
Wear safety googles

3. INTRODUCTION
I MECHI challenge organized every year in institution of mechanical engineer. This year
our challenge was to make Self Power Device. By making this device we will get to
know about new things and it will be help in the field of engineering.

Our concept is a robot that can effortlessly climb up and down stairs, as well as easily
traverse uneven terrain, Stairs have traditionally been something of a nemesis to robots,
and there is considerable footage of robots failing in the attempt, resolving this issue,
allowing robots domain to expand beyond the ground floor, the ability to climb stairs
and navigate human environments has been a major challenge for mobile robots,
Traditional approaches of tackling this problem are too slow, require complex controls,
and are too expensive for most applications.

The project needs to be fit with in a 250mm x 250 x 200 prism.

Tutors made seven groups and each group had 4 to 5 members. Each group has
3months to complete the project, and the budget which was provided to us was 275
Dhs.

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Figure 1: Stair Climb Robot (Google Image) 2017

4. DESIGN SELECTION
At first we selected drone but it was already taken by another group so we decided to
make a stair climbing robot.

There are two different types of Stair climber.

One with tank like wheels

The one with gear system

Our group selected the gear system.

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5. STAIR CLIMBING ROBOT

A robot that can effortlessly climb up and down stairs, as well as easily traverse uneven
terrain, Stairs have traditionally been something of a nemesis to robots, and there is
considerable footage of robots failing in the attempt, resolving this issue, allowing
robots domain to expand beyond the ground floor, the ability to climb stairs and
navigate human environments has been a major challenge for mobile robots, Traditional
approaches of tackling this problem are too slow, require complex controls, and are too
expensive for most applications.

Artifacts which project will deliver and how will it be delivered in terms of what
user can aspect
A robot which moves freely in a building has to be adapted to an environment made for
humans. On its way it may encounter small obstacles (up to 4 cm of height, e.g. door
steps, sills etc.) and stairs. These stairs often have nosings or ledges and sometimes
open risers. The slope of indoor stairs can vary between 25 and 42. Sometimes you
will find in residential buildings even steeper stairs, especially spiral stairs. In public
buildings stairs often have a rise s of 17cm and a run a of 29cm (slope approx. 30)
Wheeled rovers are the optimal solutions for well structured environment like roads or
habitations. But off-the road, their efficiency is very dependent on the typical size of
encountered obstacles that have to be overcome in a standard Motion mode. Which can
typically overcome obstacles of their wheel size, if friction is high enough. Adding real
climbing abilities to a wheeled rover requires the use of a special strategy and often
implies dedicated actuators or complex control procedure.
The stair climber will be more helpful to the handicapped and worker because the
wheelchair handicapped people used and the worker which they used the trolley are
very limited in mobility. Besides, lots of budget is spent in construction to work out a
special path. Sometimes it is hard or even impossible to build a path for old existing
buildings. Thus, regular wheelchairs and trolley have problem entering these buildings.
A stair climber which will help handicapped and workers to go over obstacles and
staircase.

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Figure 2: Stair Climbing Wheel Chair (Google Image) 2017

6. LITERATURE REVIEW
6.1. Battery
An automotive battery is a rechargeable battery that supplies electrical energy to a
motor vehicle. Modern SLI batteries are lead-acid type and provide 12.6 volts of direct
current, nominally 12 V. The battery is actually six cells connected serially.

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Figure 3: 12V Battery (Self-Capture) 2017

6.2. Motors
A DC motor is any of a class of rotary electrical machines that converts direct current
electrical energy into mechanical energy. The most common types rely on the forces
produced by magnetic fields.

Figure 4: 12V Motor (Self-Capture) 2017

6.3. Wheels
A circular object that revolves on an axle and is fixed below a vehicle or other object to
enable it to move over the ground.

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Figure 5: Wood Wheel (Self-Capture) 2017

6.4. Rod
A thin straight bar of wood or metal.

Figure 6: Rod (Self-Capture) 2017

6.5. Base
Base which made of Furniture Wood. Its length was 15cm width 7cm

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Figure 7: Base (Self-Capture) 2017

6.6. Shaft
A Shaft is a mechanical component, usually used to connect with chassis of vehicle
from one end to another end.

Figure 8: Shaft (Google Image) 2017

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7. 3D & 2D DESIGN
7.1. 3D Modeling Design
The modeling of the device was made in SolidWorks

Figure 9: Battery (Solid-Works) 2017

Figure 10: Motor (Solid-Works) 2017

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Figure 11: Shaft (Solid-Works) 2017

Figure 12: Front View (Solid-Works) 2017

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Figure 13: Top View (Solid-Works) 2017

Figure 14: Side View (Solid-Works) 2017

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Figure 15: Front View (Solid-Works) 2017

Figure 16: Half View (Solid-Works) 2017

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7.2. 2D Modeling Design

Figure 17: 2D Design (Solid Works) 2017

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8. MANUFACTURING PROCESS
After gathered materials we start construction.

Step 1: The first step was to make the base, rod and wheel with the help of thermocoil
and wood, by the help of saw blade in the carpenter shop. Light wood are used which
strong to hold our components.

Figure 18: Wood for Base (Self-Capture) - 2017

Step 2: The width of the base was 15cm and the length was 7cm, and the sides of
height was 7cm from both side.

Step 3: the diameter of the wheel is 7cm and cut from a pattern, 4 wheels was cut from
a pieces of wood and then attached with thermocoil.

Figure 19: Wheel (Self-Capture) - 2017

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Step 4: After making all the parts of the base and wheel which included the bottom and
the side now it was time to fix the project by using crew, wooden glue and various type
of materials.

Figure 20: Fixing the project (Self-Capture) 2017

Step 5: 2 motor of 12V with 700rpm was set at the front end on the each wheel. That
motor is taken from electronic kid car and its has axel which had a gear inside that
motor and its simply connected to each of them. Holes are made in the side of wood
base and base is connected with the help of wooden glue and screw. The motor was
attached to the base where the weight could stay balanced.

Figure 21: Motors (Self-Capture) - 2017

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Step 6: Battery was set at the base with the help of screw. There was 12volt motor
single battery was used for both motor. Battery was connected with switch to on and off
and wiring was done with soldering.

Figure 22: Fitting Battery (Self-Capture) - 2017

Step 7: We have fixed the motors in the front of two wheel, our idea was to move the
vehicle with two motors at the front of wheel. Each motor connected on single wheel
and the back wheel was lifted free to move with the force of front wheel.

9. PROBLEM FACED
Some Major problems that we used:

At first we used 4.5V motor with 150rpm but the weight of motor effected the
performance of the project. Then we used the 12V motor with 700rpm which
enhance the performance of the project a bit.
Then we faced problem during buying materials, gear and chain was not
available anywhere in the market. Then we didnt find the respective gears and
chain for our project so we decided to go for an internative which was to use two
700rpm motors on the front of the vehicle and the back two wheel of vehicle
leave free.
The wheels which used that made up of wood are heavy, so we decided to make
wheels of thermocoil.
And at last was the budged, 275 Dhs was not easier to manage.

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10. PRODUCT PRICE

The total budget given by the tutor was 275 Dhs and it was our important duty to make it
below 275 Dhs for all the components.

10.1. Materials Invoice

Components Cost
Battery of 12 Volts 40 Dhs
Two 12 Volts Motor of 25 x 2 = 50 Dhs
700rpm
Two 4.5 Volts Motors of 15 x 2 = 30 Dhs
150rpm
Thermocoil 10 Dhs
Wood Carpentering 45 Dhs
Screws, Nuts, Bolts and Glue 30 Dhs
Switch 10 Dhs
Table 1: Invoice - 2017

Total = 235 Dhs

11. TESTING
So, the project was finally ready for testing but the initial problem we faced was with the
motor. The motor (4.5 Volts of 150rpm) we were trying to put was not capable of
weighing the weight of the project so we did with the different motor of 700rpm (12
Volts).

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12. COMPETETION
Finally comes the Competition day after all the hard work. It is the day where all the
groups had to present their devices and challenge with other groups. So there were 7
groups including our group. We were the 2nd group. Group 1 made a device called
Mountain Claiming which can climb any kind of instrument expect stairs, Group 2 was
us Stair Climber Robot, Group 3 made a Drone it wasnt easy to make as it required
little bit dimension of base can unbalanced drone but group 3 done there best, Group 4
project was rotating vehicle, Group 5 made a Can Crusher which already done by last
year but this time they have more safety then before. Group 6, made a project was Fire
Fighting that the most interesting project but unfortunately it does not work and the last
Group 7 CNC Machine which also didnt work with some issues.

The Winners in this competition are:

The Drone

The Mountain Climber

The Can Crusher

But we are still happy because our project has a best idea but unfortunately it doesnt
work properly.

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13. PROJECT PLANNING

Figure 23: Project Planning Schedule (Excel) - 2017

The above figure shows the complete planning of our project work. This planning was
estimated initially and made. So we had to divide our working according to the schedule
and managed to complete the work on time. We were also assigned to create a blog
about this whole project. We have created the blog on Wix and further more information
about the project can be found out in the following link given below.

https://hamzajamil.wixsite.com/genesis

14. FURTHER IMPROVEMENT

Switch could be wireless.
Its much better to make this project by aluminum or steel.
Gear should be better, through gear all wheels get equal power through motor so
it will move smooth and easy.
Speed controller is important while claiming on stairs.

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15. CONCLUSION
Through this experiment we have developed Stair Climbing Robot for providing the
service for human in many fields like office, home, while sitting in the car etc. The
calculations and experiments we learnt that the height of the step being climbed had to
be smaller than the overall height of the robot.

On the competition day the all the group presented their devices and challenged with
each other. Overall it was an interesting day, where everyone enjoyed the Challenge.

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16. REFERENCE
Anon, (2017). [online] Available at: http://On the competition day the entire group
presented their devices and challenged with each other. Overall it was an
interesting day, where everyone enjoyed the Challenge. [Accessed 10 May 2017].

Ingham, L., Tyndall, C. and Davies, D. (2017). Stair-climbing robots are here, and
theyre ready to be used in the real world - Factor. [online] Factor. Available at:
http://factor-tech.com/robotics/22214-stair-climbing-robots-are-here-and-theyre-
ready-to-be-used-in-the-real-world/ [Accessed 11 May 2017].

Mabuchi, T., Nagasawa, T., Awa, K., Shiraki, K. and Yamada, T.

(2017). Development of a stair-climbing mobile robot with legs and wheels.

Meet the Stair Bear, a. (2017). Meet the Stair Bear, an Adorable Climbing Robot |
Make:. [online] Make: DIY Projects and Ideas for Makers. Available at:
http://makezine.com/2015/05/01/meet-stair-bear-adorable-climbing-robot/
[Accessed 13 May 2017].

Robotpark ACADEMY. (2017). How to Design a STAIR CLIMBING ROBOT 81004 -

Robotpark ACADEMY. [online] Available at:
http://www.robotpark.com/academy/how-to-design-a-stair-climbing-robot-81004/
[Accessed 12 May 2017].

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