DESIGN AND FABRICATION OF AN

AUTOMATED STAIRCASE CLIMBING TROLLEY

BY

ENUBIANOZO-OLU EMMANUEL ENG1403758

AKHARIA OGBEMUDIA JENNNINGS ENG1403737

IGBE OMONUWA RICHMOND ENG1403768

OKODUWA ISRAEL ONOSETALE ENG1303667

DEPARTMENT OF MECHANICAL ENGINEERING,

FACULTY OF ENGINEERING,
UNIVERSITY OF BENIN,
BENIN-CITY.

DECEMBER, 2019.

i
 CERTIFICATION

This is to certify that this project work was conducted by ENUBIANOZO-OLU

EMMANUEL, AKHARIA OGBEMUDIA JENNINGS, IGBE OMONUWA

RICHMOND & OKODUWA ISRAEL ONOSETALE in the Department of Mechanical

Engineering, in partial fulfillment of requirements for the award of Bachelor of

Engineering in Mechanical Engineering, University of Benin, Benin-City.

…………………………….. ……………………………..
Mr. Festus Ehi-Eromosele Date
Project Supervisor

…………………………….. …………………………….
DR. O.O. Ighodaro Date
Head of Department

…………………………….. ……………………………..
External Examiner Date

ii
 DEDICATION

This project is dedicated to God Almighty for his guidance and to our families for their

unalloyed support.

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 ACKNOWLEDGEMENT

Our most profound gratitude goes to God Almighty for his protection, wisdom and

provisions throughout the course of this project. We also thank our supervisor, Mr.

Festus Ehi-Eromosele for the coaching, mentorship and tutorship we received

throughout this period. We also appreciate our Head of Department, Dr. O.O. Ighodaro

for the knowledge he impacted on us and his unalloyed support throughout the duration

of this project.

We also appreciate our loving families for their financial support, love and

encouragement even when it seemed almost unachievable, your inexorable motivation

mustered the determination to finish.

To our course mates and all who assisted in one way or the other for the success of this

project, God bless you all and thank you.

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 ABSTRACT

In the modern world though, there are many ongoing developments in the field

of engineering. Still there exist certain difficulties in situations when it is required to

carry heavy loads over stairs. Development of lift and elevators greatly reduces the

effort of carrying heavy loads over stairs. However, lifts and elevators are not readily

available in all places like schools, colleges, universities and constructional areas. This

project aims at developing a mechanism for easy transportation of heavy loads over

stairs. The need for such arises from day to day requirements in our society. Devices

such as hand trolleys are used to relieve the stresses of lifting while on flat ground.

However these devices usually fail when it comes to carrying the load over short fleet

of stairs. Our project attempts to design an automated stair climbing trolley which can

carry objects up the stairs with less effort instead of carrying them manually .The main

objective of the project is to find an efficient and user friendly method of carrying

various objects through stairs using minimum effort from the user and to also provide a

smooth movement while climbing stairs.

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 Table of Contents
TITLE PAGE …………………………………………...……………………………. i

CERTIFICATION…………………...……………………………………..………… ii

DEDICATION …………………...…………………………….…………..………... iii

ACKNOWLEDGEMENT ………………………….………………..……………… iv

ABSTRACT ………...…………………………………………….…………….…… v

LIST OF FGURES ………………………………………..…………...……………. viii

LIST OF TABLES AND GRAPH …………...…….………………………………... ix

CHAPTER ONE .………………………………………..…………………………….. 1

1.0 Introduction.............................................................................................................1
1.1 Background to Study...............................................................................................1
1.2 Problem Statement ………..…………………...………………………………….2

1.3 Hypothesis...............................................................................................................2
1.4 Aim and Objectives.................................................................................................2
1.4.1 Aim...................................................................................................................2
1.4.2 Objectives..........................................................................................................2
1.5 Scope of study.........................................................................................................3
CHAPTER TWO...............................................................................................................4
2.0 Literature Review....................................................................................................4
2.1 Hand Trolley............................................................................................................4
2.2 Description and Types.............................................................................................5
2.3 Stair Climbing Trolley.............................................................................................6
2.4 Material Selection....................................................................................................6
2.4.1 Trolley Body (Mild Steel).................................................................................7
2.4.2 The Wheel Design (Tri-Star)............................................................................8
2.4.3 Wheel Frame.....................................................................................................8
2.5 Wheel Selection.....................................................................................................xx
2.6 Chain Drives.......................................................................................................xxiii

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 2.6.1 Advantages...................................................................................................xxiv
2.6.2 Disadvantages..............................................................................................xxiv
2.6.3 Terms Used in Chain Drive..........................................................................xxv
2.7 Electric Motors....................................................................................................xxv
2.7.1 Components of the Electric Motor..............................................................xxvii
2. 8 Battery...................................................................................................................19
2.8.1 Primary Battery............................................................................................xxxi
2.8.2 Secondary Battery.......................................................................................xxxii
2.9 Bearing Selection.............................................................................................xxxiii
CHAPTER THREE....................................................................................................xxxiv
3.0 Methodology.....................................................................................................xxxiv
3.1 Design Specification.........................................................................................xxxiv
3.2 Conceptual Design.............................................................................................xxxv
3.3 Design Factors...................................................................................................xxxv
3.4 Detail Design....................................................................................................xxxvi
3.4.1 Power Requirement....................................................................................xxxvi
3.4.2 Tri- Star Wheel Design...................................................................................27
3.4.3 Shaft Design.....................................................................................................xl
3.4.4 Chain Design.................................................................................................xlii
3.4.5 Bearing Selection........................................................................................xliii
3.4.5.1 Basic dynamic load for bearing at B (CB)................................................xliii
3.4.5.2 Basic dynamic Load for bearing at A........................................................xliii
3.4.5.3 Design Data................................................................................................xliv
3.4.6 Forces on the shaft.........................................................................................xlv
3.5 Manufacturing Specification...............................................................................xlvi
3.6 BEME ………………...……………………………………………..………… 37

CHAPTER FOUR...........................................................................................................39
4.0 Testing...................................................................................................................39
4.1 Results...................................................................................................................39
4.2 Discussion.................................................................................................................l
CHAPTER FIVE.............................................................................................................lii

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5.1 Conclusion..............................................................................................................lii
5.2 Recommendation....................................................................................................lii
REFERENCES:...........................................................................................................liii

viii
 LIST OF FIGURES

Figure 2.1 Hand Trolley 5

Figure 2.2 Mild Steel 8

Figure 2.3 Tri-Star Wheel in Motion 9

Figure 2.4 Straight Wheel Frame 9

Figure 2.5 Curved Wheel Frame 10

Figure 2.6 Quasi-Plenary Wheel Frame 10

Figure 2.7 Electric Motor 15

Figure 2.8 Rechargeable Battery 20

Figure 3.1 Manually Operated Two Wheel Trolley 25

Figure 3.2 Manually Operated Three Wheel Trolley 25

Figure 3.3 Automated Tri-Star Wheel Trolley 25

Figure 3.4 Tri-Star Wheel Design 29

Figure 3.5 Free Body Diagram of Power Shaft 30

Figure 3.6 Stress Analysis on the Shaft 35

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 LIST OF TABLES & GRAPHS

Table 3.1 Design Matrix 25

Table 3.2 Manufacturing Specifications 36

Table 3.3 Bill of Engineering Measurement and Evaluation 38

Table 4.1 Test Results 39

Graph 4.1 Graph of Distance against Load 40

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 CHAPTER ONE

1.0 Introduction

Goods transportation locally is highly dependent on manual trolleys. These

conventional trolleys have a very huge limitation when it comes to stairs; they can only

move on flat surfaces and rough terrains, moving them over a staircase is a very hectic

task. Thus, the introduction of staircase climbing trolley.

Stair climbing trolley is designed to convey the goods with less human effort. They

usually have pairs of three or more wheels provided. These combinations of wheels

work as a single unit. However, the conventional staircase climbing trolley can be

automated, thus reducing the amount of human effort required. (Hsueh, 2008)

1.1 Background to Study

The conventional trolley which has been in use for over many decades has been

a great success since its introduction, it has serve a lot of purposes, but it primary

purpose is to convey goods (light or heavy) from one point or place to another. It

limitation is due to the fact that it cannot be used to convey goods or items from a point

to another where stairs are involved. (Swansea and Mumbles 2007)

The introduction of the stair climbing trolley was to mitigate the limitations of the

conventional trolley which is primarily to convey goods on stairs. (Knowles, 1987).

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1.2 Problem Statement

In everyday life there is the need to convey goods and objects through stairs

especially in offices, schools, colleges, hotels, industries, apartments, etc. Due to the

manpower required when conveying goods through stairs using manual labour, the

trolley becomes a necessity.

However, there are obvious limitations using the conventional trolley (such as increased

human effort, increased labour time, load instability, etc.). Thus, this project is aimed at

the design and fabrication of an automated staircase climbing trolley.

1.3 Hypothesis

Stair climbing trolley will perform better than the conventional trolley because

the stair climbing trolley reduces the cost of transporting goods or materials within a

specified region and in return, it reduces the manpower required.

1.4 Aim and Objectives

1.4.1 Aim

The aim of this project is to design and fabricate an automated stair climbing

trolley.

1.4.2 Objectives

i. Design of the automated stair climbing trolley.

ii. Fabrication of the stair climbing trolley.

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 iii. Test for performance.

1.5 Scope of study

This project is limited to the design and fabrication of an automated staircase

climbing trolley.

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 CHAPTER TWO

2.0 Literature Review

A trolley is a small vehicle with wheels that can carry things. People can push

trolleys. There are different kinds of trolleys. There are shopping trolleys which are

used in supermarkets and other large stores with self-service. In American English these

are called shopping carts. Customers can put things they want to buy in the trolley and

then pay for everything at the checkout. Usually they are then allowed to wheel the

trolley with the things they have bought out to their car. Trolleys are used in airports

and some large railway stations for passengers to carry their luggage and a trolley can

also be a tea-trolley. This is a small trolley used in the house for plates, cups, saucers

and sandwiches; they are also used in the hospitals and offices. (Lyndia, 2003)

In American English "trolley" can be used to mean a tram (or streetcar). This is not to

be confused with a trolleybus which is a bus which uses electricity from an overhead

cable (like a tram).

2.1 Hand Trolley

A hand trolley is a small transport device used to move loads or goods from one

place to another; it is a very common tool used by a large number of people and

industries that transport physical products. (Wiley, 2004).

A hand truck, also known as a two wheeler, stack truck, trundle, box cart, sac barrow,

cart, dolly etc. is an L-shaped box-moving handcart with handles at one end, wheels at

4
the base, with a small ledge to set objects on, flat against the floor when the hand-truck

is upright. (Census, 2013)

Fig. 2.1

The hand trolley is mostly used to convey many or multiple goods from one place to

another at a particular time. The hand trolley eradicates and conserves time spent in

getting a job done in transporting goods.

2.2 Description and Types

A hand trolley consist of two small wheels located beneath a load bearing

platform, it has two handles on its support frame. The handles are used to push, pull and

maneuver the device and the products being conveyed are usually stacked on top of the

platform.

Different types of hand trolley exist, and the type chosen is often based on the type of

material to be moved and they include; wheeled trolley, folding trolley, garden trolley,

kitchen trolley sack trolley and stair climbing trolley.

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Emphasis and a close review will be carried out on the stair climbing trolley and also it

various parts or components will be discussed and its mode of selection.

2.3 Stair Climbing Trolley

The stair climbing hand truck is designed to reduce liability rather than

increasing it and also decreasing the cost of employing man-power to conveying goods

or loads in an organization, at home, a factory or at an institution with no lift or elevator

but stairs only.

Lifting heavy objects or loads to upper stories from the ground are strenuous tasks most

especially where there are no lifting facilities (elevators, conveyor, etc.). Moreover,

most of the buildings are structurally congested and do not have elevators or escalators,

so in such building the stair climbing trolley is used for conveying or transporting goods

over a short height (stair-case). (William, 2008).

2.4 Material Selection

Material selection is a step in the process of designing any physical object. In

the context of product design, the 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 cost of desired materials.

Hand trucks are fabricated from many different types of materials, including steel tube,

aluminum tube, aluminum extrusion and high impact plastic. Most commercial hand

trucks used for beverage and food service deliveries are rugged and very light. They are

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usually constructed from two extruded aluminum channel side rails and cast aluminum

or magnesium parts. Some of the options that may be considered are the types of

wheels, star climber, handle type and size of wheels. Other things to be considered

should be the load shape compared with the backrest shape and the environmental

conditions n which the hand truck will operate. (William, 2008).

2.4.1 Trolley Body (Mild Steel)

Mild steel also known as plain carbon steel is the common form of steel due to

its acceptable material properties in engineering and also it price compared to iron.

Carbon steel is steel with carbon content up to 2.1% by weight. The definition of carbon

steel from the American Iron and Steel Institute (AISI) states:

Steel is classified to be carbon steel when:

i. No minimum content is specified or required for chromium, cobalt,

molybdenum, nickel, niobium, titanium, tungsten, vanadium, zirconium, or any

other element to be added to obtain a desired alloying effect;

ii. The specified minimum for copper does not exceed 0.4%;

iii. Or the maximum content specified for any of the following elements does not

exceed the percentages noted: manganese 1.65%, silicon 0.6%, copper 0.6%.

7
 FIG. 2.2 MILD STEEL OR CARBON STEEL

The term “carbon steel” may also be used in reference to steel which is not stainless

steel; in this use, carbon steel may include alloy steels.

As the carbon percentage content rises, steel has the ability to become harder and

stronger through heat treating; however, it becomes less ductile. Regardless of the heat

treatment, higher carbon content reduces weldability. In carbon steels, the higher the

carbon content, the lower the melting point.

We’re using the mild steel (tube) for the trolley body due to it malleability, weight and

cost.

2.4.2 The Wheel Design (Tri-Star)

The tri-star is a novel wheel design originally by Robert and John Forsyth,

assigned to Lockheed in 1967 in which three wheels are arranged in an upright triangle

with two on the ground and one above them. If either of the wheels in contact with the

ground gets stuck, the whole system rotates over the obstruction. In the tri-star wheel

design, all three satellite wheels are simultaneously powered through a mechanical

linkage between each satellite wheel and a shaft concentric with the central hub. In the

8
original patent, the direction of the vehicle is controlled through the differential

steering. (Robert and John, 1967).

FIG. 2.3 TRI-STAR WHEEL IN MOTION

2.4.3 Wheel Frame

A specially designed wheel frame is required to hold the three wheels together

on each side of the shaft; in the conventional trolley design, the power transmission to

the single or double wheel trolley is useless to climb the stairs due to height factor or

hindrance of the stairs. The design of the straight wheel frame became more

complicated and needed to be modified with its curved or spherical shape to give proper

drive, which creates more frictional force and some of the types include;

FIG. 2.4 STRAIGHT WHEEL FRAME

9
 FIG. 2.5 CURVED WHEEL FRAME

FIG. 2.6 QUASI-PLENARY WHEEL FRAME

(Robert and John, 1967).

For these reasons, three wheels set on each side of a vehicle attached with frame were

introduced to provide smooth power transmission in order to climb stairs without much

difficulty. Frame arrangement is suitable to transmit exact velocity ratio, higher

efficiency and compact layout with reliable service, easier maintenance was possible in

case of changing or replacing any defective parts.

2.5 Wheel Selection

A wheel is a circular device that is capable of rotating on its axis, facilitating

movement or transportation or performing labour in machines. Wheels are one of the

most important and delicate parts of a mobile machine; a well selected and maintained

wheel can prevent accidents, provide better handling and offer much comfort to the

driver or owner. (James, 2007)

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The wheel selection in this project is very sacrosanct and as such was carefully thought

of for a more satisfactory usage by individuals. There are some factors which are taken

into consideration in selecting the type wheel to be used and they include;

i. Materials Used

ii. Processes involved during construction

iii. Durability of the wheel

iv. The cost of the wheel.

v. Size

vi. Environmental factors

i. Materials Used: This is by far the most important factor to focus on when

selecting a new wheel. The two main materials used to make aftermarket wheels

are steel and aluminum. The most common steel wheels are the Moto Metal

wheels that are known to be strong and light weighted. Steel wheels are

preferred for drivers who want strong and durable wheels that can withstand

anything.

Aluminium wheels such as XD wheels on the other hand are known for their

light weight nature; Aluminium wheels are also cheaper than steel wheels. There

are three distinct types of wheel materials, and they include; filled rubber,

polyurethane and steel.

1. Filled Rubber: In tires, 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

11
 tire that comes in contact with the road surface. Treads are often designed to

meet specific product marketing position.

2. Polyurethane: polyurethane (PUR or PU) is a polymer composed of a chain of

organic units joined by carbonate (urethane) links. While most polyurethane are

thermosetting polymers that do not melt when heated, thermoplastic

polyurethanes are also available. The main ingredients to make polyurethane are

isocyanate and polyols. Other materials are added to help processing the

polymer or to change the properties of the polymer.

3. Steel: steel is an alloy of iron with carbon being the primary alloying element up

to 2.1% by weight.

ii. Processes Involved During Construction: The processes involved during

construction will determine how strong, durable and reliable your wheel will be.

There is the stamped method mostly seen in steel wheels. This method allows a

more consistent composition that helps to improve the wheel’s structural

integrity. There is also the extreme heat and pressure process that is mostly used

in forged wheels such as American Force Wheels. This process is known to

create dense and durable wheels stronger than steel but lighter than that of a cast

alloy. There are also wheels made using low-pressure casting that allows for

better flexibility and malleability.

iii. Durability of the Wheel: Before selecting your desired truck wheel, it is

important to know and also to look at how durable it is. If you drive through

extreme off road terrains, you may opt for the most durable wheels made of steel

12
 such as American Racing Wheels. Durable wheels are perfect for those who

drive through rough conditions and you may have to settle for less durable

wheels such as the stylish cast wheels if you do not drive or plough through

rough terrains.

iv. Cost of the Wheel: Another factor to look out for when selecting a wheel is the

cost of the wheels. Having looked and carefully taken into considerations some

other factors listed and discussed above, one has to narrow down his list to a few

wheels. The most affordable wheels are not necessarily the cheapest wheels, so

one has to take care before making his/her final decision as to the type or kind of

will to get.

v. Size of the Wheel: When choosing the type of wheel to use for the machine, it

is important to put into consideration the size of the wheel that best suits your

requirements; different sizes for different load requirement and also to eradicate

noise or friction as a result of the optimum usage of the machine.

vi. Environmental Factors: Environmental factors such as sulphuric acid, petrol,

diesel, alcohol and much more affects the tires of the wheel and which in return

reduces the life span of the tire.

2.6 Chain Drives

In order to avoid slipping, steel chains are used. The chains are made up of rigid

links which are hinged together in order to provide the necessary flexibility for warping

around the driving and driven wheels. The wheels have projecting teeth and fit into the

13
corresponding recesses, in the links of the chain. The wheels and the chain are thus

constrained to move together without slipping and ensures perfect velocity ratio. The

toothed wheels are known as sprocket wheels or simply sprockets. These wheels

resemble to spur gears. The chains are mostly used to transmit motion and power from

one shaft to another, when the distance between the centres of the shafts is short such as

in bicycles, motor cycles, agricultural machinery, road rollers, etc. ( Khurmi, 2005)

2.6.1 Advantages

1. As no slip takes place during chain drive, hence perfect velocity ratio is

obtained.

2. Since the chains are made of metal, therefore they occupy less space in width

than a belt or rope drive.

3. The chain drives may be used when the distance between the shafts is less.

4. The chain drive gives high transmission efficiency (up to 98 per cent).

5. The chain drive gives fewer loads on the shafts.

6. The chain drive has the ability of transmitting motion to several shafts by one

chain only.

2.6.2 Disadvantages

1. The production cost of chains is relatively high.

2. The chain drive needs accurate mounting and careful maintenance.

3. The chain drive has velocity fluctuations especially when unduly stretched.

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2.6.3 Terms Used in Chain Drive

The following terms are frequently used in chain drive.

i. Pitch of the chain: It is the distance between the hinge centre of a link and the

corresponding hinge centre of the adjacent link. It is usually denoted by “p”.

ii. Pitch circle diameter of the chain sprocket: It is the diameter of the circle on

which the hinge centres of the chain lie.

2.7 Electric Motors

An electric motor is an electrical machine that converts electrical

energy into mechanical energy. Most electric motors operate through the interaction

between the motor's magnetic field and electric current in a wire winding to generate

force in the form of rotation of a shaft. Electric motors can be powered by direct

current (DC) sources, such as from batteries, motor vehicles or rectifiers, or

by alternating current (AC) sources, such as a power grid, inverters or electrical

generators. An electric generator is mechanically identical to an electric motor, but

operates in the reverse direction, converting mechanical energy into electrical energy.

Fig. 2.7 An electric motor

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Electric motors may be classified by considerations such as power source type, internal

construction, application and type of motion output. In addition to AC versus DC types,

motors may be brushed or brushless, may be of various phase (see single-phase, two-

phase, or three-phase), and may be either air-cooled or liquid-cooled. General-purpose

motors with standard dimensions and characteristics provide convenient mechanical

power for industrial use. The largest electric motors are used for ship propulsion,

pipeline compression and pumped-storage applications with ratings reaching 100

megawatts. Electric motors are found in industrial fans, blowers and pumps, machine

tools, household appliances, power tools and disk drives. Small motors may be found in

electric watches.

In certain applications, such as in regenerative braking with traction motors, electric

motors can be used in reverse as generators to recover energy that might otherwise be

lost as heat and friction.

Electric motors produce linear or rotary force (torque) intended to propel some external

mechanism, such as a fan or an elevator. An electric motor is generally designed for

continuous rotation or for linear movement over a significant distance compared to its

size. Magnetic solenoids produce significant mechanical force, but over an operating

distance comparable to their size.

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2.7.1 Components of the Electric Motor

The following listed, highlighted and discussed below are the components of an

electric motor;

2.7.1.1 Rotor
In an electric motor, the moving part is the rotor, which turns the shaft to deliver

the mechanical power. The rotor usually has conductors laid into it that carry currents,

which interact with the magnetic field of the stator to generate the forces that turn the

shaft. Alternatively, some rotors carry permanent magnets, and the stator holds the

conductors. The Rotor is a moving component of an electromagnetic system n the

electric motor, electric generator or alternator. Its rotation s due to the interaction

between the windings and magnetic field which produces a torque around the rotor’s

axis. (Nelson, 2014).

2.7.1.2 Bearings
The rotor is supported by bearings, which allow the rotor to turn on its axis. The

bearings are in turn supported by the motor housing. The motor shaft extends through

the bearings to the outside of the motor, where the load is applied. Because the forces of

the load are exerted beyond the outermost bearing, the load is said to be overhung.

(Gates, 2017)

2.7.1.3 Stator
The stator is the stationary part of the motor's electromagnetic circuit and

usually consists of either windings or permanent magnets. The stator core is made up of

many thin metal sheets, called laminations. Laminations are used to reduce energy

17
losses that would result if a solid core were used. The coil can be either iron core or

aluminum. To reduce loading losses n motors, manufacturers invariably use copper as

the conducting material n winding. (Drive; 2006)

2.7.1.4 Air Gap

The distance between the rotor and stator is called the air gap. The air gap has

important effects, and is generally as small as possible, as a large gap has a strong

negative effect on performance. It is the main source of the low power factor at which

motors operate. The magnetizing current increases with the air gap. For this reason, the

air gap should be minimal. Very small gaps may pose mechanical problems in addition

to noise and losses.

2.7.1.5 Windings
Windings are wires that are laid in coils, usually wrapped around a laminated

soft iron magnetic core so as to form magnetic poles when energized with current.

Electric machines come in two basic magnet field pole configurations: salient and non-

salient-pole configurations. In the salient pole machine the pole's magnetic field is

produced by a winding wound around the pole below the pole face. In the non-salient

pole, or distributed field, or round-rotor, machine, the winding is distributed in pole face

slots. A shaded-pole motor has a winding around part of the pole that delays the phase

of the magnetic field for that pole. (Mortensen and Beckwith, 1949)

18
Some motors have conductors that consist of thicker metal, such as bars or sheets of

metal, usually copper, alternatively aluminum. These are usually powered by

electromagnetic induction.

2.7.1.6 Commutator
A commutator is a mechanism used to switch the input of most DC machines

and certain AC machines. It consists of slip-ring segments insulated from each other

and from the shaft. The motor's armature current is supplied through

stationary brushes in contact with the revolving commutator, which causes required

current reversal, and applies power to the machine in an optimal manner as

the rotor rotates from pole to pole. In absence of such current reversal, the motor would

brake to a stop. In light of improved technologies in the electronic controller, sensorless

control, induction motor, and permanent magnet motor fields, externally commutated

induction and permanent magnet motors  are displacing electromechanically

commutated motors.

2. 8 Battery

A battery is a device consisting of one or more electrochemical cells with

external connections provided to power electrical devices such as flashlights, mobile

phones, and electric cars. (Crompton, 2000)

When a battery is supplying electric power, its positive terminal is the cathode and its

negative terminal is the anode. (Pauling and Linus, 1988).

19
Terminal marked negative is the source of electrons that will flow through an external

electric circuit to the positive terminal. When a battery is connected to an external

electric load, a redox reaction converts high energy reactants to lower energy products,

and the free energy difference is delivered to the external circuit as electrical

energy. (Klaus, 2018)

Historically the term "battery" specifically referred to a device composed of multiple

cells, however the usage has evolved to include devices composed of a single cell.

(Pistoia and Gianfranco, 2005).

Primary (single-use or "disposable") batteries are used once and discarded;

the electrode materials are irreversibly changed during discharge.

Fig. 2.8 A Rechargeable Battery

Common examples are the alkaline battery used for flashlights and a multitude of

portable electronic devices. Secondary (rechargeable) batteries can be discharged and

recharged multiple times using an applied electric current; the original composition of

the electrodes can be restored by reverse current. Examples include the lead-acid

batteries used in vehicles and lithium-ion batteries used for portable electronics such

as laptops and mobile phones. Batteries come in many shapes and sizes, from miniature

20
cells used to power hearing aids and wristwatches to small, thin cells used in smart

phones, to large lead acid batteries or lithium-ion batteries in vehicles, and at the largest

extreme, huge battery banks the size of rooms that provide standby or emergency power

for telephone exchanges and computer data centers.

Batteries are classified into two categories which are;

i. Primary battery

ii. Secondary battery

2.8.1 Primary Battery

Primary batteries, or primary cells, can produce current immediately on

assembly. These are most commonly used in portable devices that have low current

drain, are used only intermittently, or are used well away from an alternative power

source, such as in alarm and communication circuits where other electric power is only

intermittently available. Disposable primary cells cannot be reliably recharged, since the

chemical reactions are not easily reversible and active materials may not return to their

original forms. Battery manufacturers recommend against attempting recharging

primary cells. In general, these have higher energy densities than rechargeable batteries,

but disposable batteries do not fare well under high-drain applications with loads under

75 ohms (75Ω). Common types of disposable batteries include zinc-carbon batteries and

alkaline batteries. Primary batteries are designed to be used until exhausted of energy

then discarded. Their chemical reactions are generally not reversible, so they cannot be

21
recharged. When the supply of reactants in the battery is exhausted, the battery stops

producing current and its useless.

2.8.2 Secondary Battery

Secondary batteries, also known as secondary cells, or rechargeable batteries,

must be charged before first use; they are usually assembled with active materials in the

discharged state. Rechargeable batteries are recharged by applying electric current,

which reverses the chemical reactions that occur during discharge/use. Devices to

supply the appropriate current are called chargers.

The oldest form of rechargeable battery is the lead–acid battery, which are widely used

in automotive and boating applications. This technology contains liquid electrolyte in an

unsealed container, requiring that the battery be kept upright and the area be well

ventilated to ensure safe dispersal of the hydrogen gas it produces during overcharging.

The lead–acid battery is relatively heavy for the amount of electrical energy it can

supply. Its low manufacturing cost and its high surge current levels make it common

where its capacity (over approximately 10 Ah) is more important than weight and

handling issues. A common application is the modern car battery, which can, in general,

deliver a peak current of 450 amperes.

The sealed valve regulated lead–acid battery (VRLA battery) is popular in the

automotive industry as a replacement for the lead–acid wet cell. The VRLA battery uses

an immobilized sulfuric acid electrolyte, reducing the chance of leakage and

extending shelf life. VRLA batteries immobilize the electrolyte.

22
2.9 Bearing Selection

This design recommends the use of rolling bearing rather than sliding bearing

due to the following advantages of the former to the later.

i. . Low starting and running friction except at very high speeds.

ii. Ability to withstand momentary shock loads.

iii. Accuracy of shaft alignment.

iv. Low cost of maintenance, as no lubrication is required while in service.

v. Small overall dimensions.

vi. Reliability of service.

vii. Easy to mount and erect.

viii. Cleanliness.

23
 CHAPTER THREE

3.0 Methodology

The following method will be adopted towards achieving the design and

fabrication of this work;

i. Detailed design and,

ii. Fabrication and testing.

3.1 Design Specification

The following design specifications are taken into consideration;

i. Size and weight: This is a physical magnitude or bulk relative to dimensions and

how heavy an object is.

ii. Cost: this specification is a very vital as to the fact that whatever the design is, it

should be accepted and affordable by your projected market.

iii. Maintenance and Reliability: The machine or design should be able to undergo

maintenance for it to be reliable.

iv. Durability: this design specification is talking about the useful and total life of

the machine.

v. Ease of Handling: this is also an important design specification, the way and

manner of handling the design should be easy in term of operation.

vi. Aesthetic: this is relating to the exterior beauty of the design or machine and it

also plays a useful in the design acceptance in the market.

24
vii. Carriage Capacity: this is the total weight that the design or the trolley can carry.

3.2 Conceptual Design

During the design process, three designs were conceptualized. The designs are thus:

i. Design 1 (Manually operated two-wheel trolley)

ii. Design 2 (Manually operated three wheel trolley)

iii. Design 3 (Automated Tri-Star wheel trolley)

3.3 Design Factors: Below listed are some of the design factors being considered for

this project;

1. Size and Weight (0.30)

2. Cost (0.25)

3. Durability (0.15)

4. Maintenance and Reliability (0.10)

5. Aesthetics (0.10)

6. Ease of Handling (0.10)

Concept Size & Cost Durability Maintenance Aesthetic Ease of Total

Weight & Reliability Handling

(0.3) (0.25) (0.15) (0.10) (0.10) (0.10)

Design 1 8 6 6 8 4 5 6.50
2.4 1.5 0.9 0.8 0.4 0.5
Design 2 8 7 7 7 5 6 7.00
2.4 1.75 1.05 0.7 0.5 0.6

25
Design 3 7 8 7 9 8 8 7.95
2.4 2.0 1.05 0.9 0.8 0.8
Table 3.1 Decision Matrix

From the Decision Matrix above, Design 3 has the highest rating. Hence,

Design 3 will be selected for detail design.

3.4 Detail Design

i. Power requirement

ii. Tri-star wheel design

iii. Shaft design

iv. Chain drive design

v. Roller bearing design

vi. Load and stress analysis of trolley frame

3.4.1 Power Requirement

Power = force × velocity = m × g × V

Where; m = gross weight of trolley

= weight of empty trolley + maximum trolley load capacity

g = acceleration due to gravity = 9.81 m/s2

V= velocity of trolley = 0.1m/s

26
 From the market survey conducted, the average trolley load is about 15kg and

the weight of the empty trolley is 8kg.

Thus, gross weight = (15 + 8) kg = 23 kg

Also, a survey was conducted and it was observed that trolley movement is intermittent

and that trolleys move at relatively slow speed. So a speed of 0.1 m/s

Hence, Power = 23 × 1000 × 9.81 × 0.1

= 225.63W = 0.3KW

Losses in the system also have to be accounted for. So assuming 50% of the

rated power is used to overcome losses due to frictional and inertial effects.

Thus, Total Power = (50% × 225.63) + 225.63 = 338.445W = 400W

Hence, a battery with output power of 0.4KW is to be used to power the trolley.

3.4.2 Tri- Star Wheel Design

This design is dependent on how the tri- star wheel is to be positioned on the

stairs. To this end, two parameters are of prime importance;

a) The distance between the edge of the wheel on the lower stair and the face of the

next stair, x;

b) The distance between the edge of the wheel on the upper stair and the feed of the

next stair, y;

And from this, three scenarios may arise

i.e., when x < y

27
 x>y

x=y

Critically taking those scenarios in consideration, the most suitable for this design

problem will be the 3rd scenario, as in this case, the trolley will encounter very little or

no problem during motion. It should be noted that the value of x and y for the derivation

of parameters during this design can be any value but must be equal. Also, x and y are

also assumed equal to the radius of the wheel, r

i.e., x=y=r

For the design of this tri- wheel, five parameters are taken into consideration;

i. The height of the stairs, a

ii. The width of the stairs, b

iii. The radius of the wheel, r

iv. The distance between the centre of the tri- star wheel and the centre of its wheel,

v. The thickness of holder/ clamp that fox the wheel in its place on the tri- star

wheel, 2t

From the project design specifications,

28
 Fig 3.4

a = 0.12m

b = 0.25m

r = 0.05m

From the geometry,

√
2 2
R = a +b
3

√
2 2
= 0.12 +0. 25
3

= 0.16m

The maximum height of the stairs is also important and is calculated as,

a max = √ a2 +b 2−r 2

= √ 0.122 +0. 252 – 0.05 2

= √ 744

= 0.2178m

29
3.4.3 Shaft Design

Fig 3.5

0.75m

It is however noted that the weight of the shaft is negligible

Given; Power output, P = 0.4KW

Velocity, V = 0.1m/s

Diameter of sprocket, d = 0.18m

Allowable stress for material, τ = 42mpa

Twisting moment, T = P × W

V
=P×
R

P × 2×V
¿
d

400 ×2 ×0.1
¿
0.18

= 444.44Nm = 0.444KNm

Tangential force on sprocket;

30
 2T 2× 444.44
Ws = = (Khurmi, 2005)
D 0.1 8

= 4938.222N = 4.94KN

From the free body diagram above, maximum bending moment will occur at the centre

of the sprocket, (since it is simply supported)

WL 4.94 × 0.75
Thus; M = M max = =
4 4

= 0.926KNm

Equivalent twisting moment, T e =√ M 2 +T 2 (Khurmi, 2005)

¿ √ 0.296 +0.444
2 2

= 0.534KNm

π
× τ allowable ×d o ( 1−k )
3 4
Also, T e =
16

di
The shaft is hollow and (K¿ )
do

K is assumed to be 0.9

31
 π
∴ 0.534 ×10 3= × 42× 106 ×d o3 ( 1−0.94 )
16
3
3 16 ×0.534 ×10
do =
42 ×10 × π × ( 1−0.9 )
6 4

d o = 0.18m

Let, d o = 0.18m

∴ d i= K× d o

d i = 0.9×

d i = 0.162m

3.4.4 Chain Design

In an open chain drive system connecting two sprocket, it is known that the

length of belt for an open belt drive connecting the two pulleys of radii r 1and r 2 and a

centre distance x, is

2
( r +r )
L = π ( r 1+ r 2 ) + 2x + 1 2 (Khurmi, 2005)
x

Where r 1=¿ 90mm (Radius of bigger sprocket)

r 2=¿ 47.5mm (Radius of smaller sprocket)

x¿ 411mm (distance between both sprockets from their centres)

32
 22
π=¿ = 3.142
7

( 90+47.5 )2
∴ L = 3.142 ( 90+47.5 ) + 2(411) +
411

= 432.025 + 822 + 46

L= 1300.025mm

From the above equation, Ct is found that the length of the chain used is 1300

3.4.5 Bearing Selection

3.4.5.1 Basic dynamic load for bearing at B (CB)

B – Fe = [ ( x ×C r × F r )+(C t × F t) × S . F ]

Where Ct = 0

Cr = 1

X = 1 (inner race rotation)

Factor of safety, S.F = 3 (taken)

∴ B – Fe = (1 × 1 × 395.25) × 3 = 1186N

Then CB = (L10)1/b ×Fe

L10= 1680km/rev

b = 3 (since the load is considered small)

CB = (1680)1/3 x 1186 = 14,100N

3.4.5.2 Basic dynamic Load for bearing at A

A – Fe = [ ( x ×C r × F r )+(C t × F t )× S . F ]

Where x = 1

33
 Cr = 0.56

Ct = 1 (taken)

S.F = 3

Fr = 369.75N

Ft = 384.6N

∴A – Fe = (1 ×0.56 ×369.75) + (1 × 442.3) ×3

= 1,948N

Then CA = (L10)1/b ×Fe

CA = (1680)1/3 ×1948 = 23,158N

3.4.5.3 Design Data

Bearing A (non – locating bearing)

Type: deep groove bearing

Manufacturer: SKF

Fran S.K.F catalogue, page 190, with

C = 30,700N

d = 40mm
designation = 6208
Bearing B (non – locating bearing)

Type: deep groove bearing

Manufacturer: SKF

Fran S.K.F catalogue, page 190, with

C = 30,700N

34
 d = 40mm
designation = 6208

3.4.6 Force on the shaft

Fig 3.6

From the figure above shows a cantilever of length, L, carrying uniformly distributed

load, W, per unit over whole length. Thus,

Maximum deflection of beam, Ymax is given as

WL3
Ymax =
8 EI

Where, W = load (force acting on shaft)

L = length of shaft = 1.3m

I = moment of inertia

E = young modulus for mild steel (207 GN/m2)

Take Ymax = 0.001m

3
bd
I= (Rectangular moment of Inertia)
12

W = 4.94KN

Let b = 0.2m

35
 3 3
WL bd
I= =
8 EYmax 12
3 3
12WL 12× 4.94 ×1000 × 0.25
d =
3
=
8 b EYmax 8 ×207 ×10 9 × 0.2×1 ×10−3

d=
√
3 926.25
3312 ×10
5

d = 0.0141m

3.5 Manufacturing Specification

S/n Items Dimension

1. Ball bearing 4×16 × 5 mm

2. Sprocket 1 (big) D= 180mm

3. Sprocket 2 (small) D= 95mm

4. Chain L = 1300mm

5. Shaft L = 760mm

6. Frame L = 580mm, H = 1200mm

7. Rubber Wheel D=160mm

8. Mild steel hollow pipe OD=30mm,ID=26mm and L=5000mm

9. Mild steel plate L=300mm and B=400mm

10. Electric Motor (Rotor) 12KVA

11. Battery 12V

12. Bolts and Nuts 10mm

13. Rubber Handle Cover D=30.5mm

36
14. Carriage 50×50 ×58 mm

15. Cables 2mm thick

Table 3.2 Manufacturing Specification.

3.6 Bill of Engineering Measurement and Evaluation (BEME)

S/n Items Dimension Quantity Rate (#) Price (#)

1. Ball bearing 4×16 × 5 mm 2 1,500 3,000

2. Sprocket 1 (big) D= 180mm 1 4,000 4,000

3. Sprocket 2 (small) D= 95mm 1 3,000 3,000

4. Roller Chain L = 1300mm 1 4,000 4,000

5. Rubber Wheel D=160mm 6 700 4,200

6. Mild steel hollow OD=30mm,ID=26 2 5,000 10,000

pipe mm and

L=5000mm

7. Mild steel plate L=300mm and 2kg 2,000 4,000

B=400mm

8. Electric Motor 12KVA 1 5,000 5,000

(Rotor)

9. Battery 12V 1 10,000 10,000

10. Bolts and Nuts 10mm 6 each 200 1,200

11. Rubber Handle D=30.5mm 2 500 1,000

Cover

37
12. Carriage 50×50 ×58 mm 1 3,000 3,000

13. Cables 2mm thick 2 yards 700 1,400

14. Welding and - - - 10,000

finishing cost

15. Miscellaneous - - - 7,000

16. Total - - - 70, 800

Table 3.3 BEME

38
 CHAPTER FOUR

4.0 Testing

The stair climbing trolley was tested with varying loads within a fixed time

range. The distances over stairs (i.e. number of stairs) for each load at five minutes were

recorded.

It was first tested with no load to ascertain full functionality. Subsequently,

loads of 5kg, 10kg, 15kg, 20kg, 25kg and 30kg (which is the maximum load capacity

limit of the trolley) were tested on the trolley and the distance covered for each of these

loads in 5 minutes (300sec) were recorded

4.1 Results

No of Tests Load (kg) Distance (no of stairs) Time (m)

1 0 160 5

2 5 120 5

3 10 90 5

4 15 60 5

5 20 30 5

6 25 0 5

7 30 0 5

Table 4.1 Test Result

39
 Graph 4.1 Distance against load

4.2 Discussion

From the six trials with varying loads, the stair climbing trolley covered

reasonable distances four times. At loads of 25kg and 30kg, the trolley was immovable;

hence the efficiency of the stair climbing trolley can be obtained thus;

no of successful tr i als 100

Efficiency, E= ×
no of attempted tr i als 1

4 100
× = 66.67%
6 1

The trolley designed has an efficiency of 66.67%.

40
The trolley efficiency can be improved by using higher capacity electric motor and

battery so as to ensure functionality at high loads.

Alternatively, stair climbing trolleys for different capacities can be designed

depending on the maximum weight of the items to be conveyed using the trolley. At

different locations, such as malls, factories, libraries, etc. different nature of items will

need to be conveyed using the trolley. Weight-specific trolleys can be designed and

manufactured for these locations with high efficiencies leading to corresponding high

productivity in these locations.

41
 CHAPTER FIVE

5.1 Conclusion

The design of the automated staircase climbing trolley will aid in the movement

of commodities in areas which are of rough terrains and staircases and it is suitable and

easy to use. Maintenance and repair cost are low and affordable to shopping malls and

mart owners. The machine is designed to suit the lowest distance between staircases of

0.2727636m, a power rating of 0.4kw and an efficiency of 66.67%.

The machine consist of a handle, for moving the machine forward and backward, six

pairs of tyres for mobility, a basement and platform that comforts the battery, chain and

sprockets that transmit the power from the battery to the motor shafts. With all of these

mechanical parts and components, the machine is able to perform the function of

carrying commodities comfortably on staircases.

5.2 Recommendation

1. The machine should be operated on staircases of height of o.12m that is more than

0.25m wide.

2. The machine should be used only for the function it is designed for.

3. Further studies should be done on how to improve this design.

42
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44