MAHARASHTRA STATE BOARD OF

TECHNICALEDUCATION

Certificate
This is to certify that,
1 YASAR ANSARI 18705
2 IBAAD KAZI 18713
3 DEVENDRA 18715
GAIKWAD
4 FAZAL KAGDI 18718
5 AHMED KHATIB 18722

Of SIXTH Sem of Diploma In Mechanical Engineering (UA) of Institute M.H.Saboo Siddik

Polytechnic(Code:0002)has completed the team work satisfactorily in Capstone project for
the academic year 2020-2021 as pre scribed in the curriculum.

Place: Mumbai Date:

Subject Teacher Head of the Department Principal

1
 DECLARATION.

I declare that this project report entitled “(ADVANCED STAIRCASE CLIMBING

TROLLEY)” represents my ideas in my own words and where others' ideas or words have
been included, I have adequately cited and referenced the original sources. I also declare that
I have adhered to all principles of academic honesty and integrity and have not
misrepresented or fabricated or falsified any data/fact in my submission. I understand that any
violation of the above will be cause for disciplinary action by the Institute and can also evoke
penal action from the sources which have thus not been properly cited or from whom proper
permission has not been taken when needed.

YASAR ANSARI 18705

IBAAD KAZI 18713

DEVENDRA GAIKWAD 18715

FAZAL KAGDI 18718

AHMED KHATIB 18722

2
 ANNEXUE-
II

Evaluation Sheet for the Micro Project

AcademicYear:2020-2021 Name of Faculty: SHAHAB AHMED

Course: ME-6I Course Code : 22058 Semester: 6TH

Title of the Project: ADVANCED STAIRCASE CLIMBING TROLLEY.

Course outcomes addressed by the Micro Project:

 Assess the impact of the project on society

Major Learning Outcomes achieved by students by doing the Project:

A. Practical Outcomes: -

B. Unit Outcomes in Cognitive domain: -

 Design and construct a vehicle that can create an impact in the society
 A project that would help us build a better environment also sharpen and test our
skills.

C. Outcomes in Affective Domain: -

ROLL NO . STUDENT NAME MARKS OUT F 6 MARKS OUT OF 4 FOR ORAL, TOTAL OUT OF
FOR PRESENTATION,PERFORMANCE. 10
PERFORMANCE IN
GROUP ACTIVITY
18705 YASAR ANSARI

18713 IBAAD KAZI

18715 DEVENDRA
GAIKWAD
18718 FAZAL KAGDI

18722 AHMED KHATIB

3
 SUBJECT: CAPSTONE PROJECT

 OUR TOPIC: -
 Advanced Stair Case Climbing Trolley.

 AIMS/BENEFITS OF THE MICROPROJECT: -

 Can be used as material handling device.

 COURSE OUTCOMES: -
 Assess the impact of the project on society.

 UNIT OUTCOMES: -
 Design and construct a trolley that can create an impact in the society
 A project that would help us build a better environment.

 LITERATURE REVIEW :

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.

4
 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 endeavours 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.

5
 TABLE OF CONTENTS

CHAPTER NO TITLE PAGE NO

ABSTRACT 5
LIST OF SYMBOLS 8
LIST OF FIGURES 9
1.0 INTRODUCTION 10
1.1 HAND TROLLEY 10
1.1.2 DESCRIPTION 10
1.2 TYPES OF TROLLLEY 11
1.2.1 WHEELED TROLLEY 11
1.2.2 FOLDING TROLLEY 11
1.2.3 GARDEN TROLLEY 11
1.2.4 KITCHEN TROLLEY 12
1.2.5 STACK TROLLEY 12
1.3 NEED FOR STAIRCLIMBER TROLLEY 12
2.0 STAIR CLIMBER TROLLEY 13
2.1 NEW CONCEPT 13
3.0 TRI-STAR WHEEL 14
3.1 TRI-STAR WHEEL DESIGN 14
3.2 APPLICATION OF TRI-STAR WHEEL IN OUR PROJECT 14
4.0 SELECTION AND FABRICATION OF STAIR CLIMBER 15
TROLLEY
4.1 MATERIAL SELECTION 15
4.1.1 TROLLEY BODY 15
4.1.2 TRI-STAR WHEEL WEB 15
4.2 BEARING SELECTION 16
4.3 WHEEL SELECTION 17
4.3.1 TYPES OF WHEEL MATERIAL 17
4.3.1.1 FILLED RUBBER 17
4.3.1.2 POLYURETHANE 17

6
4.3.1.3 STEEL 17
4.3.2 STATIC FRICTION 17
4.3.3 VARIOUS WHEEL MATERIALS AND CO-EFFICIENT OF 18
FRICTION
4.4 WHEEL FRAME 19
4.4.1 TYPES OF WHEEL FRAMES 19
4.5 CAD MODEL OF TROLLEY 20
4.6 PROCESS INVOLVED IN FABRICATION 22
4.6.1 GAS CUTTING 22
4.6.2 PIPE BENDING 22
4.6.3 PLASMA ARC CUTTING 22
4.6.3.1 COMPONENTS OF THE SYSTEM 25
4.6.3.2 PROBLEMS FACED BY THE EQUIPMENTS 25
4.6.4 WELDING 26
4.6.4.1 ARC WELDING 26
5.0 DESIGN ANALYSIS OF TROLLEY 27
5.1 LOAD CALCULATION FOR AXLE 27
5.2 FORCE NECESSARY TO PULL THE TROLLEY 28
5.3 FORCE ANALYSIS ON WHEEL FRAME 28
6.0 COST ESTIMATION OF THE PROJECT 29
6.1 ACCOUNT STATEMENT 29
7.0 INFERENCE AND CONCLUSION 30
7.1 INFERENCE 31

7
 LIST OF SYMBOLS

SYMBOL DEFINITION

F Force

M Bending Moment

R1, R2 Reaction Forces

I Moment of inertia

(J 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

8
 LIST OF FIGURES

FIGURE NO FIGURE PAGE NO

3.1 TRI-STAR WHEEL IN MOTION 14

4.1 CLOSE-UP SHOWING SURFACE ROUGHNESS 17

4.2 CO-EFFICIENT OF KINETIC FRICTION OF VARIOUS TYRE 18

MATERIALS AND SURFACE

4.3 STRAIGHT WHEEL FRAME 19

4.4 CURVED WHEEL FRAME 19

4.5 QUASI-PLANETARY WHEEL FRAME 20

4.6 CAD MODEL OF TROLLEY SIDE VIEW 20

4.7 CAD MODEL OF TROLLEY FRONT VIEW 21

4.8 CAD MODEL OF TROLLEY ISOMETRIC VIEW 21

4.9 PLASMA ARC CUT TRI-STAR WHEEL WEB 23

7.1 MODIFIED WHEEL FRAME SETUP 30

9
 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 manoeuvre 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.

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 manoeuvre the cargo by steering it left, right or forward.

10
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 rust- proof
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.

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.

11
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.

12
 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.

13
 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

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.

14
 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

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

15
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

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

16
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.

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 surface roughness causes a "jiggle" when the
wheel is rolling.

4.3.3 Various Wheel Materials and their Co-efficient of Frictions

17
 Various Wheel materials and their co-efficient of frictions are tabulated in table 4.1 and
shown graphically in figure 4.2.

Table4.1 Various Wheel Materials and their Coefficient of friction

S.no Material Coefficient of friction

1 Rubber/concrete .85

2 Polyurethane/Concrete .5

3 Steel/Concrete .45

0.9

0.8

0.7
Rubber Vs. Concrete
0.4
Polyurethane Vs. Concrete
0.3
Steel Vs. Concrete

Coefficient of Kinetic Friction

Fig 4.2 Coefficient of kinetic friction of various tyre materials and concrete
surface

4.4 WHEEL FRAME

A specially designed wheel frame is required to hold the three wheels together
on each side of the shaft. In the existing design, the power transmission to the single or
double wheel trolley is useless to climb the stairs due to height factor of stairs. The design
of the straight wheel frame became more complicated and was needed to be modified

18
with its curved- spherical shape to give proper drive, which creates more frictional force.
For these reason, three wheel set on each side of vehicle attached with frame was
introduced to provide smooth power transmission in order to climb stairs without much
difficulty. Frame arrangement is suitable to transmit exact velocity ratio also. It provided
higher efficiency and compact layout with reliable service. Easier maintenance was
possible in case of replacing any defective parts such as nut, bolt, washer, etc.

4.4.1 Types of wheel frames

A few types of wheel frames are shown in the figure 4.3, 4.4 and 4.5.

Fig 4.3 Straight Wheel Frame

Fig 4.4 Curved Wheel Frame

19
 Fig 4.5 Quasi Planetary Wheel Frame

4.5 CAD MODEL OF TROLLEY

The cad diagrams of trolley is shown in the figure 4.6, 4.7 and 4.8.

Fig 4.6 Side View

20
 Fig 4.7 Front view

Fig 4.8 Isometric View

21
4.6 PROCESSES INVOLVED IN FABRICATION

4.6.1 Gas cutting (Oxy-Fuel cutting)

Oxy-fuel cutting is a cost-effective method of plate edge preparation for bevel and
groove welding. It can be used to easily cut rusty and scaled plates and only requires moderate
skill to produce successful results. The oxy-fuel gas cutting process creates a chemical reaction
of oxygen with the base metal at elevated temperatures to sever the metal.

We have used this cutting to cut the measured lengths of hollow mild steel pipes and flat bottom
plate as per our design.

4.6.2 Pipe bending

Tube bending as a process starts with loading a tube into a pipe bender and clamping it
into place between two dies, the clamping block and the forming die. The tube is also loosely
held by two other dies, the wiper die and the pressure die. The process of tube bending involves
using mechanical force to push stock material pipe or tubing against a die, forcing the pipe or
tube to conform to the shape of the die. Often, stock tubing is held firmly in place while the
end is rotated and rolled around the die. For some tube bending processing, a mandrel is placed
inside the tube to prevent collapsing. Much of the tooling is made of hardened steel or tooled
steel to maintain and prolong the tools life. However wherever there is a concern of scratching
or gouging the work piece, a softer material such as aluminium or bronze is utilized. Pipe
bending machines are typically human powered, pneumatic powered, hydraulic assisted,
hydraulic driven, or electric servomotor.

4.6.3 Plasma arc cutting

Plasma cutting is a process that is used to cut steel and other metals of different
thickness and sometimes other materials, using a plasma torch. In this process, an inert gas is
blown at high speed out of a nozzle; at the same time an electrical arc is formed through that
gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is
sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal
away from the cut. Through the application of CNC technology in industrial production, the
technology cut a wide range of high accuracy, low-cost and high efficiency. It gradually
achieves its purpose of high- tech computer numerical control cutting, with both computer-
controlled and plasma arc characteristics.

22
We have used plasma arc cutting for cutting four stainless steel webs for the Tri-Star wheel
arrangement which is shown in figure 4.9.

Fig 4.9 Plasma Arc cut Tri-Star wheel web

23
24
4.6.3.1 Components of the system

CNC system CNC system is an important part of the cutting machine, which consists
of a computer system, servo system, the control unit, and the executive agencies. The
computer system is made up of a keyboard, a monitor, and the unit. Servo system exploits a
computer to implement a closed-loop control of the motor and to achieve its variable speed.
Now it usually adopts communicate servo system. The control unit is central of sending a
control signal to realize the control of the computer, the motor and the solenoid valve. The
executive agencies include the electric motor and the solenoid valves and so on Programming
system is parts of auxiliary programming and nesting system for developing CNC cutting
machine. It can make the entire production process to form a whole, and to organize
systematically. After the programmed machine compiles the program on the floppy disk,
enter the cutting machine and start cutting, it can also be programmed in a simple
cutter. Gas system Gas system include the gas pipeline, pressure gauge, regulator, etc., which
can be controlled by the control system to realize the automatic on-off road of the gas.
Mechanical operation system Mechanical operation system consists of the beam, gear box,
chassis, lifting mechanism and other components.

4.6.3.2 Problems faced by the equipment .

Due to the high frequency of CPU and large power and high heat of hard drive, the
internal parts of the system is subjected to overheating, making the CNC system and cutting
machine unable to work normally and increases the requirement of industrial fans for cooling.
When each part is not used efficiently during cutting edges, taking sides, linking bridge etc., it
results in thermal deformation of the various parts and consequently results in low efficiency.
Automatic cutting cannot be achieved. There are no automatic cutting on CNC system and
parameter libraries, workers can only speak of their own experience and observation of the eye,
manually adjusting and controlling, thus it cannot effectively play productivity of the CNC
cutting machine.

25
4.6.4 Welding

Welding is a fabrication process that joins materials, usually metals

or thermoplastics, by causing coalescence. This is often done by melting the work pieces and
adding a filler material to form a pool of molten material (the weld pool) that cools to become
a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce
the weld. This is in contrast with soldering and brazing, which involve melting a lower-
melting-point material between the work pieces to form a bond between them, without melting
the work pieces.

Many different energy sources can be used for welding, including a gas flame, an electric
arc, a laser, an electron beam, friction, and ultrasound.

While often an industrial process, welding may be performed in many different environments,
including open air, under water and in outer space. Welding is a potentially hazardous
undertaking and precautions are required to avoid burns, electric shock, vision damage,
inhalation of poisonous gases and fumes, and exposure to radiation. The main Types of welding
used in industry and by home engineers are commonly referred to as MIG welding, Arc
welding, Gas welding and TIG welding.

4.6.4.1 Arc welding

These processes use a welding power supply to create and maintain an electric arc
between an electrode and the base material to melt metals at the welding point. They can use
either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes.
The welding region is sometimes protected by some type of inert or semi-inert gas, known as
a shielding gas, and filler material is sometimes used as well.

We have used Arc-Welding to join trolley parts together. The completed prototype of the
trolley is shown in figure 4.10 and 4.11.

26
 CHAPTER 5

DESIGN ANALYSIS OF TROLLEY

5.1 LOAD CALCULATION FOR AXLE

Length of the axle =0.44m Distance between welds = 0.40m

Load applied/ carried = 30 kg (distributed equally by the welds to the axle)

=15 kg through each weld = 147.15N

Weight of the trolley = 20kg (uniformly distributed throughout the axle)

=196.2 N

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

From equilibrium equation∑ F = 0

And ∑ M = 0

Find reaction at the supports,

R1= 190.314N ; R2= 190.314N

Calculate the maximum bending moment for the beam, M(max) =6.7155 N-m

Considering FOS =1.5, M(max) =10.07N –m

Bending equation,

M (J E

= =

I y R

Substituting M(max) =10.07 N-m

I= ^

Y=D

27
(J = 3.8 Nmm2)

Bending stress for the given material can be assumed to be 0.66×yeild strength

Thus, the allowable bending stress for the given material is 165 N/mm^2

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

Thus the design is safe.

5.2 FORCE NECESSARY TO PULL THE TROLLEY

F. x = W . y

F= .W

5.3 FORCE ANALYSIS ON WHEEL FRAME

W1= weight of object to be carried W2= weight of the trolley

Re = reaction force on one side F = force applied (on one lever)

R0 = distance of centroid from centre of wheel

K = distance between centre of wheel and line of action of weight

W1 + W2 (− Fsin8) . k = Fcos8. jR2 2— k2

Recos<p = Fcos8

Resin<p + Fsin8 = W1 + W2

Re = (Fcos8)2 + ( W1 + W2 2— Fsin8)

2tan<p

W1 + W2 − 2Fsin8

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 CHAPTER 6

COST ESTIMATION OF THE PROJECT

The total cost of the project is tabulated in table 6.1.

Table 6.1 Account Statement.

ACCOUNT STATEMENT:

Sr.No Item Description Rate Quantity Price₹

1 Rubber Wheels OD=150mm 250 each 6 pcs 1500

2 Ball Bearing Deep groove, SKF6006 60 each 8 pcs 1500

3 S.S. grade304 250mmx900mm 200/kg 3.5kg 800

4 M.S. hollow pipe OD=30,ID=26 - 4m long 300

5 Pipe Bending Costs Handle Pipes 20 each 2 40

6 M.S. plate 300mmx400mm 55/kg 1.7kg 150

7 Pipe and plate cutting - 10 per cut 15 150

costs
8 Plasma arc Cutting - 50 each 4 400

9 M.S. L angle 1inch - 1 120

10 Material for Shaft & - - - 170

Bearing housings
11 Turning & Facing for - - 400
Bearings housings &
shaft
12 Washer and Cotter pin - - - 50

13 Welding and Finishing - - - 1500

costs
Total: 7080

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 CHAPTER 7

INFERENCE AND CONCLUSION

7.1 INFERENCE

After its fabrication, we inferred few limitations like large noise production while
moving the trolley up and down the stairs. In order to reduce the noise production the design
of the wheel frame is to be modified such that line passing through the mid-point of the
trolley wheel should pass through the mid-point of the step. The modified wheel CAD model
is shown in figure 7.1.

Fig 7.1 Modified Wheel Frame Setup

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7.2 CONCLUSION

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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