GUJARAT TECHNOLOGICAL UNIVERSITY

Chandkheda, Ahmedabad

MARWADI EDUCATION FOUNDATIONS GROUP OF INSTITUTIONS

A
Project Report
On

INNOVATIVE COMPACT LOAD CARRIER

In fulfilment for the award of degree
B. E. Semester – VIII
(Mechanical)
Submitted by: GROUP ID (75236)

Sr. Name of student Enrollment No.

1 Nikunj Gohil 130970119511
2 Bhumit Navapara 130970119937
3 Yash Tank 130970119556
4 Parth Tanna 130970119557

Prof. Ronak Kamdar DR. Bhavesh Kanabar

(Assistant Professor) (Head of the Department)
 Marwadi Education Foundation, Rajkot
Faculty of Engineering / Technology
Mechanical Department
2016
CERTIFICATE

This is to certify that Yash Tank (130970119556) of B.E. Semester vii

(Mechanical Engineering) has completed his project work titled
“Innovative Compact Load Carrier” satisfactorily in partial fulfilment
for requirement of Mechanical Engineering course, Gujarat Technical
University, Ahmedabad, in the academic year 2016-2017.

Date: ____________________

Internal Guide Head of the Department

Prof. Ronak Kamdar Prof. Bhavesh Kanabar
 ACKNOWLEDGEMENT

First of all, we thank the almighty for providing us the strength and courage to

present the project. I avail this opportunity to express our sincere gratitude

towards Prof. Bhavesh Kanabar Head of mechanical engineering department

(Faculty of Technology), for permitting us to conduct the project.

I express my cavernous sense of obligation and gratitude to our Guide Prof.
Ronak Kamdar for his genuine guidance and constant encouragement
throughout this project work. I am highly obliged as my honorable guide for
providing me such an opportunity to carry out research work under his continuous
guidance. Also we are very thankful to Marwadi University workshop faculties
who supported us in getting our model ready.

I also wish to express my heartfelt appreciation to my family, colleagues and

many who have rendered their support for the successful works towards the
completion of the research work, both explicitly and implicitly. We also thank to
our friends who suggested right way for the improvement of our project, they gave
us complete support for the construction of our project according to guideline. We
deeply acknowledge mutually to all project supporter for their never ending
encouragement, moral support and patience during the preparation of this project.
 ABSTRACT

This product is mainly used for transporting loads from one place to another. We
can even transport loads from one floor to another as it will be able to climb stairs.
Our product is designed in such a way that it will be able to climb stairs. So
it will very useful in transporting loads in industries from one floor to the next
and eventually decrease the cost of using lifts. 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.
 1 Introduction

1.1 HAND TROLLEY

2 1.1.2 Description
3 1.2 TYPES
OFTROLLEY
4 1.2.1 Wheeled
trolley
5 1.2.2 Folding
Trolley

1.2.3 Garden Trolley

1.2.4 Kitchen Trolley
1.2.5 Sack Trolley
1.3 NEED FOR STAIR CLIMBER TROLLEY
1.4 Advantages of load carrier

2. Problem Identification
2.1 Document Purpose
2.2 Problem Definition
2.3 Intended audience
2.4 Product scope
2.5 NEW CONCEPT

3. Literature Survey
4. Design, Methodology & Implementation Strategy

4.1 Design
4.2 Types of wheel frames
4.3FORCE ANALYSIS OF TRI-WHEEL

4.3 Material selection:

4.3 Design Engineering Canvas:
5. Summary
6. References
List of figures
 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.

FIG 1-HAND TROLLY

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

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, aluminum 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
aluminum. 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.

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, aluminum steel,
and aluminum excursion.
 1.4 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.

1.4 Advantages of load carrier

Our product which we are planning to develop can carry heavy loads easily.
It can also transport heavy goods safely through difficult areas where there is risk too
good to be damaged.
It is designed in such a way that it reduces the effort that it reduces the work as
compared to current load carriers
This product also saves the time for transferring the load from one place to another
which increases the capacity of the work in which the load is to be used.
Our product is designed in such a way that it can carry load through the stairs
and very rough areas like off-road areas.
This is a very compact product which makes it easy to carry anywhere and can
transfer any type of load.
The material used in this product is very strong which makes it reliable.
It is an economic product.
 CHAPTER 2
Problem Identification

2.1 Document Purpose

The product which we are planning to develop is mainly used to transfer load from
one place to another epically from that spaces or areas from where it is difficult
to transfer load by trolleys also. For example: - Stairs, Rough areas, etc.... The
other purpose of this product is to develop a compact load carrier which can be
carried anywhere.

2.2 Problem Definition

We had visited an industry and there it came into our notice that the labor using
the cart for the transportation of goods manufactured were facing severe problems
as the storage area was quite higher than the manufacturing or production deck
thus to transfer those goods in cart they had to overcome the stairs which quite
difficult for the them so an idea struck to our mind that if the wheel arrangement
of the cart will be changed such that the stairs or the hurdles can be easily
overcome than it would be easy for a labor to complete that task.

2.3 Intended audience

Our main focus for our product is to be used in industries to carry heavier loads
like mechanical tools.

Common people can use our product in their houses to carry household stuff to
transfer it from one floor to another also they can take it to family picnics or at
airports to carry their luggage.
2.4 Product scope

We are developing this project to carry heavier load and it will be used in
industries to transfer heavy loads like heavy mechanical tools as well as it will
also be applicable for household uses like carrying suitcases and ice boxes which
is compact and easy to handle and can be carried anywhere. Our product is very
economic so anyone can afford it.
So, if anyone buys our product he/she will be able to use as multipurpose carrier
like carrying household things also he can take this carrier to airports or railway
stations to carry their luggage.

2.5 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.
 CHAPTER 3
Literature Survey

Sr Publishing
Authors/Inventors years
Summary/Conclusion
no.

1 Mr. Pratik H. Rathod, Mr. 2013 Lifting objects, loads such as books, food
Ravi R. Mishra,Mr. Nitin A. grains etc. to store above the ground level, or
Waghamare even patients to move upper level from ground
is not easy job, especially where there is no
lifting facilities (elevator, conveyer, etc)
Moreover, in most of the buildings in the world
does not have elevators or escalators.

2 D. A. Bell, J. Borenstein, S. 1994 An assistive navigation system for wheelchairs

Levine, Y. Koren and L. A. based on mobile robot obstacle avoidance
Jaros,

3 D. Miller and M. Slack 1995 Design and testing of a low-cost robotic

wheelchair prototype

4 D. M. Brienza and J. Angelo 1996 A force feedback joystick and control algorithm
for wheelchair obstacle avoidance.

5 R. Borgolte, R. Hoelper, H. 1995 Intelligent control of a semi-autonomous omni-

Hoyer, H. Heck, W. Humann, directional wheelchair
J. Nezda, I. Craig, R. Valleggi
and A. M. Sabatini

6 V. Krovi and V. Kumar 1997 Modeling and control of a hybrid mobility

system

7 S. Hirose, M. Usa, N. 1991 Terrain adaptive quadru-track vehicle HELIOS-

Ohmori, S. Aoki and K. III.
Tsuruzawa

8 S-M. Song and K. J. Waldron 1987 Geometric design of a walking machine for
optimal mobility.

9 People Weekly, Tom 1989 The versatile load carrier was designed by
Houston him.

10 H. F. M. Van der Loos, S. J. 1988 Development of an omni-directional mobile

Michalowski and L. J. Leifer vocational assistant robot.

11 J. Borenstein and Y. Koren, 1991 IEEE Transactions on Systems, Man and

Tele-autonomous guidance Cybernetics.
for mobile robots

12 T. Houston and R. Metzger 1992 Combination wheelchair and walker apparatus

13 Prajan Pradip Gondole , 2015 The present invention relates to hand trucks
Kamlesh Diliprao Thakre intended for transporting heavy load and more
particularly, to an improved and simplified
hand truck which is adopted to move heavy
loads easily up and down from the stair; with
the help of this truck we can lift the load easily
up and down from stairs. Due to this the man
effort is reduced and time to lift the load is also
reduced.

14 Hossain, Nafis A. 2010 Lifting recurring loads like books, food grains
Chowdhury, Rubaiat I. Linda etc. to store upper level, or even patients to
move upper level is not easy job, especially
where there is no lifting facilities (elevator).The
project introduces a new horizon for the
transportation of the loads over the stair. Most
of the buildings of the country are structurally
congested and unavailing of elevator facility so
it is difficult and laborious to lift up heavy loads.
 CHAPTER 4
Design, Methodology & Implementation Strategy

4.1 Design

The main aim of our project is to make the work of labors easy and fast. So we
observed the labors carrying the loads through cranes or normal carts and then
designed a new compact cart of ours which will be helpful not to only to carry
loads from one place to another but also it can climb stairs by applying just a
normal push. Also it won't be affected by normal obstacles like rocks etc.

The rough design is made by the using dimension of normal cart design, after
that edited the design to fulfill our purpose. Then we applied some knowledge
of stresses and strains, bending capacity, etc. with the help of Theory of the
Machine Design book.

Then using the solid works software, we created final 3Ddesign.This design
fulfills all need of the consumer and also it is very compact that makes our
design perfect.
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

FIG 2-MOTION OF THREE WHEELS

4.2 Types of wheel frames
A few types of wheel frames are shown in the figure.

FIG 3-Straight Wheel Frame FIG 4-Curved Wheel Frame

FIG 5- Quasi Planetary Wheel Frame

Wheel Frame Selected – Quasi planetary Model made of stainless steel

grade 304.
 Profile analysis Tri-Star wheels on stairs:

FIG 6-PROFILE ANALYIS OF WHEEL DIA 6” AND

WHEEL CENTER DISTANCE 8”

FIG 7-PROFILE ANALYIS OF WHEEL DIA 5” AND

WHEEL CENTER DISTANCE 8”
9yy777777

FIG 8-PROFILE ANALYIS OF WHEEL DIA 6” AND

WHEEL CENTER DISTANCE 7”

FIG 9-PROFILE ANALYIS OF WHEEL DIA 5” AND

WHEEL CENTER DISTANCE 7”
  Tri-Star wheel frame analysis result:

By using trial and error method wheel diameter 6’’ & wheel to wheel center distance
8’’ is appropriate for stair climbing process.
 CAD model of stair climbing trolley

FIG 10-FRONT VIEW FIG 11-SIDE VIEW

FIG. 12-ISOMATRIC VIEW

4.4 FORCE ANALYSIS OF TRI-WHEEL

Fsinθ

F cosθ
R
(R2-K2)1/2

K
Resinφ
Re

Recosφ

(W1+W2)/2

FIG 13-Forces acting on the system

W1= weight of objects to be carried

W2= weight of the hand cart

Re = reaction force on one side

F = force applied (on one lever)

R = 18 cm

k= 14.5 cm

𝑊1+𝑊2
( − 𝐹𝑠𝑖𝑛𝜃) . 𝑘 = 𝐹𝑐𝑜𝑠𝜃. √𝑅 2 − 𝑘 2 (1)
2

𝑊1+𝑊2
𝑅𝑒 = √(𝐹𝑐𝑜𝑠𝜃)2 + ( − 𝐹𝑠𝑖𝑛𝜃)2 (2)
2

𝑊1+𝑊2−2𝐹𝑠𝑖𝑛𝜃
𝑡𝑎𝑛𝜑 = (3)
2𝐹𝑐𝑜𝑠𝜃

𝑅𝑒 𝑐𝑜𝑠𝜑 = 𝐹𝑐𝑜𝑠𝜃 (4)

𝑊1+𝑊2
𝑅𝑒 𝑠𝑖𝑛𝜑 + 𝐹𝑠𝑖𝑛𝜃 = (5)
2
4.3 Material selection:

Chromoly

Alloy steels are designated by AISI four-digit numbers. They are more responsive to
mechanical and heat treatments than carbon steels. They comprise different types of
steels with compositions which exceed the limitations of B, C, Mn, Mo, Ni, Si, Cr, and Va
in the carbon steels.

AISI 4130 alloy steel contains chromium and molybdenum as strengthening agents. It has
low carbon content, and hence it can be welded easily. The datasheet given below
provides more details about AISI 4130 alloy steel

Chemical properties
The chemical composition of AISI 4130 alloy steel is listed in the following table.

Element Content (%)

Iron, Fe 97.03 – 98.22
Chromium, Cr 0.80 – 1.10
Manganese, Mn 0.40 – 0.60
Carbon, C 0.280 – 0.330
Silicon, Si 0.15 – 0.30
Molybdenum, Mo 0.15 – 0.25
Sulfur, S 0.040
Phosphorous, P 0.035

Physical properties
The following table shows the physical properties of AISI 4130 alloy steel.

Properties Metric Imperial

Density 7.85 g/cm3 0.284 lb/in³
Melting point 1432°C 2610°F
Mechanical properties

The mechanical properties of AISI 4130 alloy steel are outlined in the following table.

Properties Metric Imperial

Tensile strength, ultimate 560 MPa 81200 psi
Tensile strength, yield 460 MPa 66700 psi
190-210 27557-
Modulus of elasticity
GPa 30458 ksi
Bulk modulus (Typical for steel) 140 GPa 20300 ksi
Shear modulus (Typical for steel) 80 GPa 11600 ksi
Poissons ratio 0.27-0.30 0.27-0.30
Elongation at break (in 50 mm) 21.50% 21.50%
Reduction of area 59.6 59.60%
Hardness, Brinell 217 217
Hardness, Knoop (Converted from Brinell hardness) 240 240
Hardness, Rockwell B (Converted from Brinell hardness) 95 95
Hardness, Rockwell C (Converted from Brinell hardness, value below
17 17
normal HRC range, for comparison purposes only.)
Hardness, Vickers (Converted from Brinell hardness) 228 228
Machinability (Annealed and cold drawn. Based on 100% machinability
70 70
for AISI 1212 steel.)

Welding
Welding of AISI 4130 steel can be performed by all commercial methods.

Heat Treatment
AISI 4130 steel is heated at 871°C (1600°F) and then quenched in oil. This steel is usually heat-
treated at temperatures ranging from 899 to 927°C (1650 to 1700°F).

Forging
Forging of AISI 4130 steel can be performed at 954 to 1204°C (1750 to 2200°F).

Hot Working
Hot working of AISI 4130 steel can be done at 816 to 1093°C (1500 to 2000°F).
Cold Working
AISI 4130 steel can be cold worked using conventional methods.

Annealing
AISI 4130 steel can be annealed at 843°C (1550°F) followed by air cooling at 482°C (900°F).

Tempering
Tempering of AISI 4130 steel can be performed at 399 to 566°C (750 to 1050°F), depending on
the desired strength level.

Hardening
Hardening of AISI 4130 steel can be done with cold working or heat treatment.

 Material testing

FIG. 14-COMPRESSION AND TENSILE FORCE MEASURING MACHIN

 Testing results
4.3 Design Engineering Canvas:

Ideation Canvas
Product Development Canvas
AEIOU Canvas
Empathy Summary
Business model canvas
 CHAPTER 5
Summary

The innovative load carrier cart is designed in such a manner that it can overcome
the hurdles or the step that a normal load carrier cart can’t overcome on! And in the
structure of wheel there have been an arrangement done with 3 wheels on a side, we
can say 3 on 3-wheel arrangement, this is the main innovation which can make dis
cart way better than normal load carriers. The material used also differ from normal
carts as it increases the cart's strength and many other properties and furthermore it
can also handle in various situations as it is compact and has multiple uses! Which
are commercial and industrial.

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.
 CHAPTER 6
References

For reference we used books like Design Data book for designing our product
in the best possible way so that it can give best outcome, also we used Material
Science & Metallurgy to find best material for our product so it can be used to
withstand maximum load with minimum use of the resources.
Below website, that we used for our report

 https://www.google.co.in

 https://en.wikipedia.org/wiki/CNC

 http://www.weavetech.com

we are thankful to our guide…………………………. for giving us right

directions and suggestion.

 Appendix D – Periodic Progress Reports

Enrollment No : 130970119556 College : Marwadi Education Foundation's Group Of

Institutions-Faculty Of Technology, Rajkot

Student Name : Tank Yashkumar Nanjibhai Department : Mechanical Engineering

Mobile No : 9727673689 Discipline : BE

Email : yashtank5000@gmail.com Semester : Semester 7

PPR Details

Time Interval : -

Periodic Progess Report : First PPR

Project Innovative Compact Load Carrier

:

Status : Reviewed (Freeze )

1. What Progress you have made in the Project ?

Initially we had search some materials related to our project and did work on them.later we have made a rough sketch or we
can say design of our project's model with help of the software such as auto cad.so basically we have virtual reference of our
project with us.

2. What challenge you have faced ?

the model we are working on needs to be more compact and reliable or lets say durable to overcome our main motto so in
order to achive it we have faced some problems.

3. What support you need ?

we basically need higher researched or knowledge data and the proper guidance related to our project.

4. Which literature you have referred ?

the design data book and the research papers.

Comments

1/2
Comment by Internal Guide :

None

Comment by External Guide :

None

Comment by HOD :

None

Comment by Principal :

None

Comment by University Admin :

None
Appendix B – Plagiarism Report