REPORT

ON

BIN TIPPER
28th March 2021

PREPARED FOR
Ingenious Mechathon V2

PREPARED BY
TEAM 11
Abel Mathew Jacob
Aditya Jha
Boddu Harsha
Tapasvi Bhatt (Team Leader)

All members of ASME BITS Pilani Student Chapter

 TABLE OF CONTENTS

1. INTRODUCTION
2. DESIGN SPECIFICATIONS
3. MATERIAL SELECTION
4. MANUFACTURING PROCESSES
5. THEORETICAL CALCULATIONS
6. SIMULATIONS
 INTRODUCTION

This is a report based on the designing of a Bin Tipper with a capacity of lifting 100kg load.
Autodesk Fusion 360 and ANSYS Software has been used to design and simulate the structural
integrity of the different parts of this Tipper. Student License of the same software was invoked
for this.

Research done during the construction of the model has been documented in this report to ensure
that the theoretical and practical feasibility of the design is reviewed and scrutinized to desirable
depths.

Our effective and robust designs as well as the calculations done, and the material selection gives
a modular and affordable design that also ensures the effective working of the component as well
as suitable for a wide range of vehicles in 3-15 ton range with just minor adjustments.

You can have a look at all the videos and supporting documents at HERE
 DESIGN SPECIFICATIONS

1. IDEA BEHIND THE DESIGN

● A robust calculation and research on the dimensions and placement of the bin tipper
was done. (Calculations done at last)
○ The dimensions and placement are arranged in a way, considering the
maximum load of the bin, that the tipper may have to encounter and its
locational effects on the vehicle.
● The basis for the calculations was the TATA 709g LPT truck, weighing approx.
7.8ton.
● The ease of manufacturing and simplicity of the component was the primary aim.
● A modular design was implemented using the Fusion 360 software to effectively
reduce the material and increase the effectiveness of the component.
● The design is made such that the Bin-Tipper is readily attachable to any vehicle and
location, provided the availability of chassis rails (which are easily accessible in
most trucks).
● The main working part of the Tipper is Yellow in color and can be attached easily
to any vehicle using the attachment points using simple nut-bolts.
● We have used bolts and pin connections in the model to get more flexibility and
modularity in design.

2. DIMENSIONS AND OTHER SPECIFICATIONS

• Weight of the Component ≈ 20 𝐾𝑔 (𝑖𝑛𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝑎𝑙𝑙 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 𝑎𝑛𝑑 𝑎𝑐𝑐𝑒𝑠𝑠𝑜𝑟𝑖𝑒𝑠)

• Net Volume of the Component = 2.208 × 10 6 𝑚𝑚3 (𝐵𝑎𝑠𝑖𝑐 𝑏𝑜𝑑𝑦 𝑣𝑜𝑙𝑢𝑚𝑒)
• Material Used: Steel ASTM A36 (Mild Steel (𝜌 = 7.85𝑔/𝑐𝑚3 ))
 MATERIAL SELECTION

We decided to choose Mild Steel for our structure as it provides immense flexibility in
manufacturing as well as high durability and strength. Some of its properties are

1. High tensile strength

2. High impact strength
3. Good ductility and weldability
4. Good malleability with cold-forming possibilities

Along with these properties, the mild steel is economically cheap and the carbon percentage 0.05-
0.25% in it makes it more ductile and in contrast to this material like cast iron are brittle. As here
the bin tipper is being used to lift the bin, the ductile material like mild steel is more suitable to
use. This research is also complemented by the simulation which suggests that Mild steel is a safe
material to use as there is no maximum stresses reached in the entire structure made out of mild
steel.

MANUFACTURING PROCESSES

● In manufacturing of design (Bin Tipper) the ‘arms’ are casted, and the chassis rails would
have to be welded at the back or the side of the truck using bolts.
● Bolts have been utilized for the design for the more flexibility in attachment.
 COST ANALYSIS

● Cost of the steel = 65/- per kg

● Cost of the manufacturing along with steel includes 150/- per Kg
● Since the weight of the part is around 20 Kgs, considering the steel and manufacturing cost
we can estimate the total build cost to be around Rs 3000.
● Some optional accessories can also be used inside our Tripper to increase its effectiveness
and robustness, although it's not necessary for its usage
● The actuator which we are using for the design is obtained as a Standard Component from
Autodesk Fusion 360 and costs around 4500 /- but is completely optional and hence can be
neglected, as a manual wing system can be employed in its
place.(https://robu.in/product/linear-actuator-stroke-length-200mm7mm-s-
1500n12v/?gclid=Cj0KCQjw0oCDBhCPARIsAII3C_GscQBWWzfsJQyuk9jzfQDYqiG
5CNznWNOnRBMVSNcMM-v17CUy6k4aAg94EALw_wcB)
● Overall Cost analysis

Item Weight(fr Mate Lab

No of
Sl.N om Material Labour Total
Name(according Importance Fusion
piece rial our Cost Breakup
o. s Cost Cost Cost
to CAD file.) 360) Rate Rate

1 Lift System Necessary 9521.959 1 0.065 618.927335 0.085 809.366515 1428.29385

2617.63875
2 Arm Necessary 3964.483 2 0.065 515.38279 0.085 673.96211 1189.3449

Important, But
3 Actuator other options 1 5500 5500 0 5500 13617.63875
available
11000
Important, But
High Torque
4 other options 1 5500 5500 0 5500
Motor
available

Optional
5 Under Bar (Support 7265.415 2 0.065 944.50395 0.085 1235.12055 2179.6245
Material)
4817.3463 4817.3463
Optional
6 Vertical Bar (Support 4396.203 4 0.065 1143.01278 0.085 1494.70902 2637.7218
Material)

18434.98505

Can also be accessed at this link.

 CALCULATIONS

● For the calculations, we have considered 2 cases. For the first case, the tipper is attached
to the back of the truck and for the second one, it is attached to one of the sides.
● As previously mentioned, the attachment can be easily removed and attached to any other
location without much effort as bolts are used for attaching the tipper.
● By looking at the calculations, one can easily conclude that the toppling of the truck is
nearly impossible by the attachment of a small load of 100 kg at the back or to the side of
the truck.

Case 1: If bin is attached at the back of truck

Here as the bin is attached near the rear wheel there is a chance of toppling about the rear wheel,
and we can deduce that from the torque equation. Here is the diagram below, when ‘theta’ becomes
90 degrees the torque due to force would be maximum.

Fig: The angular position of the bin

𝐹𝑜𝑟 𝐵𝑎𝑐𝑘 − 𝐿𝑜𝑎𝑑𝑖𝑛𝑔 𝐶𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛 →

Fig: FBD for back loading

𝑀𝑜𝑚𝑒𝑛𝑡 𝑑𝑢𝑒 𝑡𝑜 𝐹 ⇒ 𝐹 × 𝑏
3.8 7500 × 9.8 × 3.8
𝑀𝑜𝑚𝑒𝑛𝑡 𝑑𝑢𝑒 𝑡𝑜 𝑚𝑔 ⇒ 𝑚𝑔 × =
2 2
 𝑇𝑜𝑝𝑝𝑙𝑖𝑛𝑔 𝑐𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛 ⇒ 𝑁 2 =0

𝑇𝑎𝑘𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡 𝑎𝑏𝑜𝑢𝑡 𝑡ℎ𝑒 𝑟𝑒𝑎𝑟 𝑤ℎ𝑒𝑒𝑙 𝑓𝑜𝑟 𝑡𝑜𝑝𝑝𝑙𝑖𝑛𝑔 𝑐𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛,

3.8
𝐹×𝑏 = ∗ 𝑚𝑔 = 139650 𝑁
2

𝐺𝑖𝑣𝑒𝑛 𝑡ℎ𝑎𝑡 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑖𝑛 𝑖𝑠 100 𝑘𝑔, 𝐹 = 9.8 × 100 𝑁

980 × 𝑏 = 139650
𝑏 ≈ 142.5𝑚 ⇒ (𝑊ℎ𝑖𝑐ℎ 𝑐𝑎𝑛𝑛𝑜𝑡 𝑏𝑒 𝑡ℎ𝑒 𝑐𝑎𝑠𝑒)

𝑁𝑜𝑤, 𝐴𝑠𝑠𝑢𝑚𝑖𝑛𝑔 ∶ 𝑏 ≈ 3.8 𝑚

𝑤𝑒′𝑙𝑙 ℎ𝑎𝑣𝑒 𝐹 = 36750 𝑁 ⇒ 𝑚 𝑏𝑖𝑛
= 3750 𝐾𝑔𝐻𝑒𝑛𝑐𝑒 𝑖𝑓 𝑡ℎ𝑒 𝑏𝑖𝑛 𝑤𝑒𝑟𝑒 𝑜𝑓 3750 𝐾𝑔 , 𝑡ℎ𝑒𝑛 𝑡𝑜𝑝𝑝𝑙𝑖𝑛𝑔 𝑐𝑜𝑢𝑙𝑑 ℎ𝑎𝑣𝑒 𝑏𝑒𝑒𝑛 𝑎𝑛 𝑖𝑠𝑠𝑢𝑒. 𝐵𝑢𝑡, 𝑎𝑠 𝑡ℎ𝑒 𝑚𝑎𝑥 𝑎
− 𝑚𝑎𝑠𝑠 𝑖𝑠 100𝐾𝑔, ℎ𝑒𝑛𝑐𝑒 𝑡ℎ𝑒 𝑡𝑟𝑢𝑐𝑘 𝑤𝑜𝑢𝑙𝑑 𝑠𝑢𝑟𝑒𝑙𝑦 𝑛𝑜𝑡 𝑡𝑜𝑝𝑝𝑙𝑒 𝑜𝑣𝑒𝑟.

Case 2: If bin is attached to the side of the truck

Here as the bin is attached to the side and there is a chance of toppling about the wheels near to
which the piece is attached, and we can deduce that from the torque equation. And here again when
‘theta’ becomes 90 degrees, the torque due to force would be maximum.

𝐹𝑜𝑟 𝑆𝑖𝑑𝑒 − 𝐿𝑜𝑎𝑑𝑖𝑛𝑔 𝐶𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛

𝐹𝑜𝑟 𝑡𝑜𝑝𝑝𝑙𝑖𝑛𝑔, 𝑓𝑖𝑟𝑠𝑡 𝑘𝑒𝑒𝑝𝑖𝑛𝑔 𝑊 = 𝑚 𝑏𝑖𝑛 𝑚𝑎𝑥 × 𝑔 = 980 𝑁 𝑎𝑛𝑑 𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝑓𝑜𝑟 𝑏

2.155
𝑊 × 𝑏 = 𝑚𝑔 ×
2
2.155
980 × 𝑏 = 7500 × 9.8 ×
2
𝑏 ≈ 80𝑚
𝑏 = 80𝑚 𝑖𝑠 𝑡𝑜𝑜 𝑙𝑎𝑟𝑔𝑒 𝑓𝑜𝑟 𝑎 𝑡𝑟𝑎𝑠ℎ 𝑐𝑜𝑙𝑙𝑒𝑐𝑡𝑜𝑟 𝑎𝑛𝑑 ℎ𝑒𝑛𝑐𝑒 𝑐𝑎𝑛′𝑡 𝑏𝑒 𝑎 𝑐𝑎𝑠𝑒.

𝐾𝑒𝑒𝑝𝑖𝑛𝑔 𝑏 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 (𝑠𝑎𝑦) ≈ 2 𝑚

2.155
𝑊 × 𝑏 = 𝑚𝑔 ×
2
2.155
𝑊 × 2 = 7500 × 9.8 ×
2
𝑊 ≈ 39598 𝑁
𝑚 𝑏𝑖𝑛−𝑚𝑎𝑥 ≈ 4040 𝐾𝑔
𝑚 = 4040 𝐾𝑔 𝑖𝑠 𝑡𝑜𝑜 𝑙𝑎𝑟𝑔𝑒 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑝𝑟𝑜𝑏𝑙𝑒𝑚 𝑠𝑡𝑎𝑡𝑒𝑚𝑒𝑛𝑡
𝐻𝑒𝑛𝑐𝑒, 𝑡ℎ𝑒 𝑡𝑟𝑢𝑐𝑘 𝑤𝑜𝑛′𝑡 𝑡𝑜𝑝𝑝𝑙𝑒 𝑖𝑛 𝑡ℎ𝑖𝑠 𝑐𝑎𝑠𝑒 𝑡𝑜𝑜.
You can have a look at all the videos and supporting documents at HERE
 SIMULATION

The following stress simulation suggests that for “the load of 100kg” used the maximum stress
has not been reached for the mild steel.

Using the ANSYS Simulation software we simulated our design model on different conditions to
test the deformation and stress retaining capabilities.

1. MESHING

Nodes 23214

Elements 109989

Physics Preference Explicit

Element Order Linear

Element Size 50 m

Bounding Box Diagonal 1.8703 m

Average Surface Area 1.2778E-003 m2

Minimum Edge Length 9.8049E-007 m

2. STRESS ANALYSIS

● Stress analysis was performed to check for any failures occurring in the presence of the
applied for by the bin.
● Von-mises criteria was chosen over the Tresca for the analysis as it is the most widely
used criteria around the globe due to its high accuracy and dependability.

Fig: Stresses in the structure due to the weight of the bin

Fig: Position of maximum stress

 Maximum Stress 4.4409E=007 Pa

Minimum Stress 7.3053E-004 Pa

Average Stress 1.7986e+006 Pa

3. DEFORMATION ANALYSIS (TOTAL DEFORMATION)

● Total deformation analysis was done and the maximum deformation due to the applied load
came out to be 5.3478e-004 m which seems well under the dangerous limits.
● We also notice that the deformation in the area with the maximum stress is also well under
the limits thereby proving that the supports provided are aiding the design in being more
solid and robust.

Fig: Total Deformation

 Fig: Total deformation for the area under maximum stress

Minimum Deformation 0m

Maximum Deformation 5.3478E-004 m

Average Deformation 9.1888E-005 m