BASIC CALCULATIONS:

1.Design of Frame:

Frame design for safety FOR 25*25*3 L angle mild steel channel

b = 25 mm, d= 25 mm, t = 3 mm.

Consider the maximum load on the frame to be 20 kg.

Max. Bending moment = force*perpendicular distance

= 20*9.81*325

M = 63765 Nmm

We know,

M / I = σb / y

M  = Bending moment

I   = Moment of Inertia about axis of bending that is; Ixx

y  = Distance of the layer at which the bending stress is consider

(We take always the maximum value of y, that is, distance of extreme fiber
from N.A.)

E = Modulus of elasticity of beam material.

I = bd3 /12

= 25*25^3 / 12

I = 32552.08 mm4

σb = My / I

= 63765 *12.5 / 32552.08

σb = 24.48 N /mm2

The allowable shear stress for material is σallow = Syt / fos

Where Syt = yield stress = 210 MPa = 210 N/mm2

And fos is factor of safety = 2

So σallow= 210/2 = 105 MPa = 105 N/mm2

Comparing above we get,

σb < σallow i.e

24.48 < 105 N/mm 2

So design is safe.
Motor Specification:
Motor selection for wheels
Given
Diameter for wheel=300mm
Weight of wheel with assembly is =6kg
Torque required for one motor
Torque=force*radius of wheel
=6*9.81*150
=9564.75Nmm
=9.5 Nm
Therefore we are selecting motor with 9.5 torque.

By battery,

Voltage = 12V, Current = 5Amp, Speed = 60 RPM

We know that, P = V*I = 12*5 = 60W

P = 2*π*N*T/60

60 = 2*π*60*T/60

T = 9.5 Nm

 
SHAFT CALCULATION:
Material of shaft = M.S.

M σb
=¿ …………………….(1)
I Y
Bending moment=force*perpendicular distance

π 4
I= *d
64

Bending moment= force*perpendicular distance

=5*9.81*225

=11036.25Nmm
For diameter 20mm,

π 4
I= *d
64

π
= *204
64

=7853.98
 And ,Y =10

Therefore ,
σb = My / I

11036.25 σb
=¿
7853.98 7.5

σb=1.40*10

=14 N/mm2
The allowable shear stress for material is σallow = Syt / fos

Where Syt = yield stress = 210 MPa = 210 N/mm2

And fos is factor of safety = 2

So σallow= 210/2 = 105 MPa = 105 N/mm2

Comparing above we get,

σb < σallow i.e

14 < 105 N/mm 2

So design is safe.