DESIGN AND FABRICATION OF STAIR CLIMBER TROLLEY

A PROJECT REPORT

Submitted by

PANNEER SELVAM R 621320114074

SIVA S 621320114096
SUJEETH G 621320114098

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
IN

MECHANICAL ENGINEERING

KONGUNADU COLLEGE OF ENGINEERING AND TECHNOLOGY

(AUTONOMOUS)

THOTTIYAM, TRICHY – 621215

ANNA UNIVERSITY: CHENNAI-600 025

MAY 2023

i
 KONGUNADU COLLEGE OF ENGINEERING AND TECHNOLOGY
(AUTONOMOUS)
NAMAKKAL- TRICHY MAIN ROAD, THOTTIAM
DEPARTMENT OF MECHANICAL ENGINEERING

COLLEGE VISION & MISSION STATEMENT

VISION

“To become an Internationally Renowned Institution in Technical Education, Research

and Development by transforming the students into Competent Professionals with
Leadership Skills and Ethical Values.”

MISSION
 Providing the Best Resources and Infrastructure.
 Creating Learner centric Environment and Continuous Learning.
 Promoting Effective Links with Intellectuals and Industries.
 Enriching Employability and Entrepreneurial Skills.
 Adapting to Changes for Sustainable Development.

DEPARTMENT VISION & MISSION STATEMENT

VISION
To endeavor the excellence in Mechanical Engineering field globally by producing
competent and confident graduates to face the future challenges.
MISSION
 Provide transformative education to students and improving their skills to face the global
challenges in Mechanical and Allied Engineering.
 Nurture innovation, attitude, creativity, core competency and serve the society through
requisite infrastructure and environment.
 Inculcate real world challenges, emerging technologies and endeavor the students to
become entrepreneurs or employable.

ii
 KONGUNADU COLLEGE OF ENGINEERING AND TECHNOLOGY
(AUTONOMOUS)
NAMAKKAL- TRICHY MAIN ROAD, THOTTIAM
DEPARTMENT OF MECHANICAL ENGINEERING

PROGRAM EDUCATIONAL OBJECTIVES (PEOs)

 PEO I: Graduates shall excel in the field of design, thermal, materials and
manufacturing, as successful engineers or researchers or as entrepreneurs.
 PEO II: Graduates will analyze problems, design solutions and develop products as a
team member in advanced industrial projects.
 PEO III: Graduates shall have professional ethics, team spirit, life-long learning, good
oral and written communication skills and adopt corporate culture, core values and
leadership skills.

PROGRAM SPECIFIC OUTCOMES (PSOs)

 PSO1: Professional skills: Students shall understand, analyze, design and develop
integrated equipment, thermal devices and composite components.
 PSO2: Competency: Students shall qualify at the State, National and International level
competitive examination for employment, higher studies and research.

PROGRAM OUTCOMES (POs)

Engineering Graduates will be able to:
1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering
fundamentals, and an engineering specialization to the solution of complex engineering
problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences, and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering problems
and design system components or processes that meet the specified needs with

iii
 appropriate consideration for the public health and safety, and the cultural, societal, and
environmental considerations.

4. Conduct investigations of complex problems: Use research-based knowledge and

research methods including design of experiments, analysis and interpretation of data,
and synthesis of the information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and
modern engineering and IT tools including prediction and modeling to complex
engineering activities with an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to
assess societal, health, safety, legal and cultural issues and the consequent
responsibilities relevant to the professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional
engineering solutions in societal and environmental contexts, and demonstrate the
knowledge of, and need for sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities
and norms of the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or
leader in diverse teams, and in multidisciplinary settings.
10.Communication: Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able to comprehend
and write effective reports and design documentation, make effective presentations,
and give and receive clear instructions.
11.Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one’s own work, as a
member and leader in a team, to manage projects and in multidisciplinary
environments.
12.Life –long learning: Recognize the need for, and have the preparation and ability to
engage in independent and life-long learning in the broadest context of technological
change.

iv
 ANNA UNIVERSITY: CHENNAI 600 025
BONAFIDE CERTIFICATE

This is to certify that the project report “DESIGN AND FABRICATION OF STAIR
CLIMBER TROLLEY” is the Bonafide work of “PANNEER SELVAM R
(621320114074), SIVA S (621320114096), SUJEETH G (621320114098)” who carried out
the project work under my supervision.

SIGNATURE SIGNATURE

Dr.D. JAGADEESH., M.E., Ph.D., Mr.S.K.KARTHIKEYN., M.E.,

HEAD OF THE DEPARTMENT SUPERVISOR
ASSOCIATE PROFESSOR
Dept. of Mechanical Engineering, Dept. of Mechanical Engineering,
Kongunadu College of Engineering Kongunadu College of Engineering
& Technology, & Technology,
Thottiyam, Trichy. Thottiyam, Trichy.

Submitted for the viva-voce examination held on ……………………...

INTERNAL EXAMINER EXTERNAL EXAMINER

v
 ACKNOWLEDGEMENT

We express our sincere thanks to our beloved Chairman Dr.PSK R.PERIASWAMY.,

for providing us immense facilities in our institution.

We proudly render our sincere thanks to our Principal Dr.R.ASOKAN., M.S.,

M.Tech., Ph.D., for the facilities and the encouragement given to complete this project.

We proudly render our thanks to our Dean (R&D) Dr.J.YOGAPRIYA., M.E., Ph.D.,
for their effective leadership encouragement and supportive guidance for this project.

We feel peak of pleasure in expressing our heartiest thanks to Dr.D.JAGADEESH.,

M.E., Ph.D., Head of the Department, Department of Mechanical Engineering who always
used to act as our pivot.

We sincerely acknowledge our Project Coordinator Mr.G.SELVAKUMAR, M.E.,

( Ph.D.)., Assistant Professor, Department of Mechanical Engineering for his continuous
support to complete this project.

We sincerely acknowledge our Internal Project Guide Mr.S.K.KARTHIKEYN.,

M.E., Associate Professor, Department of Mechanical Engineering for his valuable guidance
and encouragement to do the project in a successful manner.

We sincerely acknowledge our External Project Guide Mr.Mohanraj MILLWRIGHT

INDUSTRY PVT.LTD, Coimbatore, for his valuable guidance and encouragement to
complete the project in a successful manner.

Further, We sincerely thank all the Faculties and Technical Staff of our department
and my friends for their kind assistance and help rendered completing this project in
abundantly satisfying manner.

Finally, We thank from the bottom of hearts to our loving parents who understood and
satisfy all my needs.

vi
 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 trucks 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 truck 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.

vii
 TABLE OF CONTENTS

CHAPTER NO TITLE PAGE NO

ABSTRACT vii

LIST OF TABLES xi

LIST OF FIGURES xii

LIST OF SYMBOLS xiii

1. INTRODUCTION 1
1.1. HAND TROLLEY 1
1.1.1. DESCRIPTION
1.2.TYPES OF TROLLLEY 2
1.2.1. WHEELED TROLLEY 2
1.2.2. FOLDING TROLLEY 2
1.2.3. GARDEN TROLLEY 3
1.2.4. KITCHEN TROLLEY 3
1.2.5. STACK TROLLEY 3
1.3.NEED FOR STAIRCLIMBER TROLLEY 3
2. LITERATURE REVIEW 4
1.
2.
2.1.LITERATURE REVIEW 4
3. METHODOLOGY & PROBLEM IDENTIFICATION 8
3.1.METHODOLOGY 8
3.1.1. INTRODUCTION 8
3.1.2. FLOW CHART 9
3.2.PROBLEM IDENTIFICATION 10
3.3.NEW CONCEPT 10
viii
4. DESCRIPTION OF LINKAGES & TRI-STAR WHEEL 12
4.1.LEVER 12
4.1.1. CLASSES 12
4.2.FORCES 13
4.3.TRI-STAR WHEEL 14
4.3.1. TRI-STAR WHEEL DESIGN 14
4.3.2. APPLICATION OF TRI-STAR WHEEL IN OUR

PROJECT 15

5. MATERIAL SELECTION AND FABRICATION 16

5.1.MATERIAL SELECTION 16
5.1.1. TROLLEY BODY 16
5.1.2. TRI-STAR WHEEL WEB 16
5.2.BEARING SELECTION 17
5.3.WHEEL SELECTION 18
5.3.1. TYPES OF WHEEL MATERIAL 18
5.3.1.1. FILLED RUBBER 18
5.3.1.2. POLYURETHANE 18
5.3.1.3. STEEL 19
5.3.2. STATIC FRICTION 19
5.3.3. VARIOUS WHEEL MATERIALS AND
CO-EFFICIENT OF FRICTION 19
5.4.WHEEL FRAME 20
5.4.1. TYPES OF WHEEL FRAMES 21
5.5.MATERIAL PURCHASE 22
5.6.CAD MODEL OF TROLLEY 22
5.7. METHOD SELECTION FOR FABRICATION 24
5.7.1. GAS CUTTING 24
5.7.2. PIPE BENDING 24
5.7.3. PLASMA ARC CUTTING 24

ix
 5.7.3.1. COMPONENTS OF THE SYSTEM 25
5.7.3.2. PROBLEMS FACED BY THE EQUIPMENTS 26
5.7.4. WELDING 27
5.7.4.1. ARC WELDING 27
5.8.PROTOTYPE OF STAIR CLIMBER TROLLEY 28
6. DESIGN ANALYSIS OF TROLLEY 29
6.1.LOAD CALCULATION FOR AXLE 29
6.2.FORCE NECESSARY TO PULL THE TROLLEY 32
6.3.FORCE ANALYSIS ON WHEEL FRAME 33
7. COST ESTIMATION OF THE PROJECT 35
8. DISCUSSION 36
8.1.DISCUSSION 36

CONCLUSION 37

REFERENCES 38

x
 LIST OF TABLES

TABLE NO. TABLE PAGE NO.

3.1 COMPARISON BETWEEN STAIR CLIMBING

NORMAL TWO WHEELED TROLLEY 11

5.1 VARIOUS WHEEL MATERIALS

AND CO-EFFICIENT OF FRICTION 20

7.1 ACCOUNT STATEMENT 35

xi
 LIST OF FIGURES

FIGURE NO. FIGURE PAGE NO.

4.1 Lever classes 13

4.2 First class lever 14
4.3 Tri-star wheel motion 15
5.1 Close-up showing surface roughness 19
5.2 Co-efficient of kinetic friction of
various tyre materials and surface 20
5.3 Straight Wheel Frame 21
5.4 Curved Wheel Frame 21
5.5 Quasi-Planetary Wheel Frame 21

5.6 CAD model of trolley Side View 22

5.7 CAD model of trolley Front View 23

5.8 CAD model of trolley Isometric View 23

5.9 Plasma Arc Cut Tri-Star Wheel Web 25

5.10 Prototype of Stair Climber Trolley Side View 28

5.11 Prototype of Stair Climber Trolley Front View 28

7.1 Modified Wheel Frame Setup 26

xii
 LIST OF SYMBOLS

SYMBOL DEFINITION

F Force

M Bending Moment

R1, R2 Reaction Forces

I Moment of inertia

σ 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

xiii
 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 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

1
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 rubber as well.
Welded steel and rubber 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 and rubber 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. It is also lightweight but is

usually able to carry heavy loads, and can fold to take up less space when not in

2
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. 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.

1.2.1 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.

1.3 NEED FOR STAIR CLIMBER TROLLEY

Lifting heavy objects to upper stories or lifting patients to upper levels

from the ground are easy, 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.

3
 CHAPTER 2
LITERATURE REVIEW
2.1. LITERATURE REVIEW

Stair climbing truck, Mr. Pratik H. Rathod, Mr. Ravi R. Mishra,

Mr. Nitin A. Waghamare in sept-2013, Published in International Journal
of Emerging Trends in Engineering and Development

Lifting objects, loads such as books, food grains etc. to store above the
ground level, or 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. In
this case human labors are considered to be the only solution. Labor is
becoming costly as well as time consuming in the developed countries, where
growth rate is getting negative. This problem can be solved if a vehicle can lift
loads while travelling through stairs. The project introduces a new option 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. The stair climbing hand truck can play an
important role in those areas to lift loads over a short height, like libraries,
hospital, and in construction area. The vehicle, which can move upper level
through stairs, or run in very rough and rocky surfaces, is called stair climbing
hand truck or say stair climbing vehicle.
Stair climber trolleys have a total of six wheels, three on each side. They
are set in a triangular pattern. The uppermost wheel rests on the upper step, with
the other two wheels set on the lower step. This allows you to apply leverage as
you pull the trolley up a set of stairs. Though this project had some limitation as
a first step of making any Stair Climbing hand truck, it was a pioneer project.
During the test run of this project, it was realized that it would capable of
carrying heavy load without suffering any deformation or local fractures if it

4
would go into real world production at an ideal scale. Though the initial cost of
the project seemed to be higher but more accurate manufacturing would shorten
this.

Stair climbing hand trolley, Prajan Pradip Gondole, Kamlesh Diliprao

Thakre in april-2015, Published in Journal of Emerging Technologies and
innovative Research (JETIR)

The present invention relates to hand trucks 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.

After studying various options it was decided to build a hand truck that could
be carry load across stair, also it was decided to power it manually so as to keep
it in reach of many users. This will enable efficient handling of goods across
stairs with less human energy. before delving into the theory behind complex
stair-climbing mechanisms, it should first be noted that it is possible to climb
stairs using an ordinary wheel.
The large wheels necessary for this task make this method of stair-climbing
somewhat undesirable. Also, the climbing motion produced by simply rolling
over stairs is a jarring motion rather than a smooth one. In addition, the
frictional force between the wheel and the edge of the stair must be sufficient to
allow the wheel to grab and roll over the stair. A friction coefficient of too small
a magnitude will cause the wheel to slip against the stair rather than climb.

A problem with prior art hand trucks or carrying carts is that is difficult for
the operator to keep the truck under control when going down the stairs, and it
is even more difficult to move heavy loads up on stairs because the operator is
substantially pulling the load and the truck. It is common to have braking device
operable to help prevent the truck from running away during its movement

5
down the stairs. Another problem with existing hand trucks and carrying carts is
that they are unsatisfactory for transporting heavy products. The trucks typically
have pair of ground engaging wheels which wear quickly because of the heavy
loads bearing downwardly directly on the wheels.

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.

Stair Climbing Vehicle, Md. A. Hossain, Nafis A. Chowdhury, Rubaiat I.

Linda in jan-2010, Published in International Journal of Research
Publications in Engineering And Technology
Lifting recurring loads like books, food grains 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. The stair climbing vehicle can play an
important role in those areas to lift loads over a short height, like libraries,
hospital, and in construction area. The vehicle, which can move upper level
through strain, or run in very rough and rocky surfaces, is called stair climbing
vehicle.
In the initial design, each wheel contained frame, a sun wheel and three
planetary wheels. The planetary wheel was connected with the sun wheel
through an idler. The purpose of using the idler was to rotate the planetary
wheels in the same direction of sun wheel. Each planetary wheel was aligned in
a straight line with idler and sun wheel. The straight wheel frame takes more
6
thrust to tilt the wheel frame to engage next planetary wheel. The length of each
arm is high and thus creates vibration and the vehicle would be unstable. In the
present design, the wheel frame was made curve so that the front surface of the
arm could not collide with the edge of the stair.

7
 CHAPTER 3
METHODOLOGY & PROBLEM IDENTIFICATION

3.1. METHODOLGY

3.1.1. INTRODUCTION

What is methodology? A methodology is a plan-of-attack, especially

when that planof-attack is used repeatedly. This might be obvious, but the word
methodology is related to the word method. In fact, a methodology is a system
of methods followed consistently. Scientists, for example, use various
methodologies as they perform experiments. It might seem like the world is
nothing but chaos and disorder. But sometimes there is a method to this
madness. And sometimes there is a methodology.

In this chapter, there will be a lot of information about the process and
journey throughout the making of our final project. There will be flow chart
showing the process of us making the whole project. This flow chart will
explain the processes we took. Next, is the Gantt Chart, which will show the
actual and planning throughout all the 13 weeks of our final year project
journey. However, in this chapter, we also will show 3 methods we researched
to carry our final year project. Although, these 3 methods have its own pros and
cons and it will be explained individually by the teammates.

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.
Down the staircases and to up come small obstacles like holes and bumps on its
path. Among those 3 methods are gas cutting, pipe bending and welding. Most
common way of making Mr. Carry is by using the method of welding. This
method has a lot of advantages and disadvantages. Hence, in this chapter we
will discuss about these 3 methods and which one we chosen.

8
3.1.2. FLOW CHART

Start

Material selection

Material purchase

Method selection

Fabrication

Yes
No

Test
Run

Analysis Data

Report Writing

End

9
3.2. PROBLEM IDENTIFICATION

Devices such as hand trolleys are used to relieve the stress of lifting while
on flat ground. A typical hand trolley consists of two wheels located beneath a
load-bearing platform. however, these devices usually fail when it comes to
carrying the load over short fleet of stairs. By replacing two small wheels
instead of Tri-Star wheels which enable us to carry load up and down the stairs.
To overcome 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 in stairs. Moreover, some of the buildings are
structurally do not have elevators or escalators. This project can introduce a new
option for the transportation of loads over the stairs.

3.3. 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.

10
 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.

Comparison Stair climbing trolley Two wheeled trolley

Stair climbing Easy Difficult

Driving on rough
Easy Difficult
surfaces

Number of wheels Six Two

Ground contact of
Two wheels on each side One wheel on each side
wheels

Load distribution Even load distribution on two Load is distributed only one
on ground wheels each side wheel on each side

Table 3.1 Comparison between stair climbing and Normal two wheeled trolley

CHAPTER 4

11
 DESCRIPTION OF LINKAGES & TRI-STAR WHEEL

4.1. LEVER

Levers can be used to exert a large force over a small distance at one end
by exerting only a small force over a greater distance at the other.

In physics, a lever (from French lever, "to raise", c.f. a levant) is a rigid
object that is used with an appropriate fulcrum or pivot point to multiply the
mechanical force that can be applied to another object. This leverage is also
termed mechanical advantage, and is one example of the principle of moments.
A lever is one of the six simple machines.

EARLY

The earliest remaining writings regarding levers date from the 3rd century
BC and were provided by Archimedes. "Give me the place to stand, and I shall
move the earth." is a remark of Archimedes who formally stated the correct
mathematical principle of levers In ancient Egypt, constructors used the lever to
move and uplift obelisks weighting more than 100 tons.

4.1.1. CLASSES

There are three classes of levers representing variations in the relative

locations of the fulcrum, the load and the force

 Class 1: the fulcrum is located between the applied force and the load.
Example: the crowbar.
 Class 2: the load is situated between the fulcrum and the force. Example:
the wheelbarrow.
 Class 3: the force is applied between the fulcrum and the load. Example:
the human elbow joint on flexion.

4.2. FORCES
12
 For the classical mechanics formulas to work, or to be a good
approximation of real world applications, the lever must be made from a
combination of rigid bodies, i.e. a beam and a rigid fulcrum. Any bending or
other deformation must be negligible.

Figure 4.1. Lever classes

A pivoted rigid bar used to multiply force or motion, sometimes called
the lever and fulcrum (see illustration). The lever uses one of the two conditions
for static equilibrium, which is that the summation of moments about any point
equals zero. The other condition is that the summation of forces acting in any
direction through a point equal zero. See also Inclined plane.

13
 Figure 4.2. First class lever

If moments acting counter clockwise around the fulcrum of a lever are

positive, then, for a frictionless lever, FBb − FAa = 0, which may be rearranged
to give Eq.

If FB represents the output and FA represents the input, the mechanical

advantage, MA, is then given by Eq.

Applications of the lever range from the simple nutcracker and paper drill
to complex multiple-lever systems found in scales and in testing machines used
in the study of properties of materials.

4.3. TRI-STAR WHEEL

4.3.1 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 tri star, 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.

14
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.

Fig4.3 Tri-Star wheel in motion

4.3.2. 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.

15
 CHAPTER 5

SELECTION AND FABRICATION OF STAIR CLIMBER TROLLEY

5.1 MATERIAL SELECTIONS

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.

5.1.1 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).

5.1.2 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

16
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 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.

5.2 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 (e.g., a hub or shaft). 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. Ball bearings tend to have lower load capacity for their size than other
kinds of rolling-element bearings due to the smaller contact area between the
balls and races
Bearing Selected - SKF 6006 Open Deep Groove Ball Bearing
30x55x13mm
Inside Diameter: 30mm
Outside Diameter: 55mm
Width: 13mm

17
 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.
5.3 WHEEL SELECTION
Wheel material selected – Filled rubber
5.3.1 Types of Wheel Material

5.3.1.1 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.

5.3.1.2 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.

5.3.1.3 Steel

18
 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.

5.3.2 Static friction

The surface of the wheel and what it is rolling on are not perfectly
smooth. They have irregularities.

Fig5.1 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.
5.3.3 Various Wheel Materials and their Co-efficient of Frictions
Table5.1 Various Wheel Materials and their Coefficient of friction

S.no Material Coefficient of friction

1 Rubber/concrete 0.85
2 Polyurethane/Concrete 0.5
3 Steel/Concrete 0.45

19
 0.9

0.8

0.7

0.6

0.5
Rubber Vs. Concrete
0.4
Polyurethane Vs. Concrete
0.3 Steel Vs. Concrete
0.2

0.1

0
Coefficient of
Kinetic Friction

Fig 5.2 Coefficient of kinetic friction of various tyre materials and concrete
surface

5.4 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 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.

20
5.4.1 Types of wheel frames

Fig 4.3 Straight Wheel Frame

Fig 4.4 Curved Wheel Frame

Fig 4.5 Quasi Planetary Wheel Frame

Wheel Frame Selected – Quasi planetary Model made is stainless
steel grade 304.

21
5.5 MATERIAL PURCHASE

The process of materials purchasing is crucial to collect and obtains all

the materials needed. In this process a lot of research on the places and suppliers
that the materials are going to be purchase is done. This step is important so that
the risk of material wasting, or money-loss will not happen. However, to carry
out material purchasing, a well-made purchasing plan needed to be made. First,
the suppliers will be contacted to make sure the availability of the materials.
Then, the calculation of the amount of materials needed and the price of the
materials. After that, surveys of price must be carried out to determine the better
selling prices. Then finally, the purchases could be made.

5.6 CAD MODEL OF TROLLEY

The body of the trolley was assembled and welded along with the Tri-Star
wheel arrangement. The cad diagram of trolley is shown in the figure--.

Fig 5.6 Side View

22
 Fig 5.7 Front view

Fig 5.8 Isometric View

23
5.7 METHOD SELECTION FOR FABRICATION

5.7.1 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.
5.7.2 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 aluminum or bronze is utilized. Pipe bending machines
are typically human powered, pneumatic powered, hydraulic assisted, hydraulic
driven, or electric servomotor.
We have employed human powered-tube bending process to bend two
mild steel hollow pipes to make 60o bent handles.
5.7.3 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

24
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.

We have used plasma arc cutting for cutting four stainless steel webs for
the Tri-Star wheel arrangement.

Fig 4.9 Plasma Arc cut Tri-Star wheel web

5.7.3.1 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.

(a) The computer system is made up of a keyboard, a monitor, and the unit.

25
 (b) 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.
(c) The control unit is central of sending a control signal to realize the
control of the computer, the motor and the solenoid valve.
(d) The executive agencies include the electric motor and the solenoid valves
and so on.

Programming system 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.

5.7.3.2 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

26
own experience and observation of the eye, manually adjusting and controlling,
thus it cannot effectively play productivity of the CNC cutting machine

5.7.4 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.

5.7.4.1 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

27
filler material is sometimes used as well.We have used Arc-Welding to join
trolley parts together.

5.7 PROTOTYPE OF STAIR CLIMBER TROLLEY

Fig 5.10 Side View

Fig 5.11 Front View

28
 CHAPTER 6

DESIGN ANALYSIS OF TROLLEY

6.1 LOAD CALCULATION FOR AXLE

Fig 6.1 Force diagram

F = 150 kg = 1471.5 N

Under equilibrium condition sum of all vertical forces is zero, Calculation of

end reaction at

support-

RA – 735.75– 735.75 + RB = 0

RA+RB =1471.5N

Taking moment about A

∑mA = 0
(735.75*50.8) + (735.75*609.2)–(RB *660) =0
RB = 735.75 N
RA = 735.75 N

Where,
RA – vertical reaction at A RB – vertical reaction at B Shear Force calculation
S.F at A= 1962

29
S.F at C & D =0
S.F at A &B = 735.75 N
Bending moment at A =0
Bending moment at B =0

Bending moment at C 735.75 * 50.8 = 37376.1 N mm

Bending moment at D 735.75* 50.8 = 37376.1 N mm Considering the
maximum bending moment

M= π/32 *d3 * σb σb = σyt / factor of safety

For cast iron Yield Stress σyt = 570N/mm2

Therefore, σb = 570 / 3 = 190 N/mm2 37376.1 = π/32 *d3 * 190

d=12.60 mm say 15mm

(Considering F.S. = 3) (From data book)
d=15mm

Fig 6.2 Shear force and Bending moment diagram

30
Coefficient of rolling resistance [Crr] = (0.0048)

(18/D)1/2(100/W)1/4
Where,
D = Diameter of the rolling wheel in inches

W = Load acting normal to the wheel on the frame

Rolling Resistance [F] = (W.Crr)/R

The diameter of the wheel = 15 cm

= 5.90 in

The maximum load acting normal to the

Base plate = 150 kg

= 330.69 lbs.

Crr = (0.0048) (18/D)1/2 (100/W)1/4

Crr = (0.0048) (18/5.90)1/2 (100/330.69)1/4

Crr = 0.00621 F = (330.69*0.00621)/2.95

F = 0.696 lbs F = 0.315 kg

F = 3.090 N

Rolling resistance determines the stability of rolling wheel.

31
6.2 FORCE NECESSARY TO PULL THE TROLLEY

W
x

Maximum load determination

F . x=W . y

y
F= . W
x

32
6.3 FORCE ANALYSIS ON WHEEL FRAME
Fsinθ

F cosθ
R
( Ro 2-K2)1/2

K
Resinφ
Re

Recosφ

(W1+W2)/2

Forces acting on the system

Where,

W1= weight of object to be carried

W2= weight of the trolley

Re = reaction force on one side

F = force applied (on one lever)

Ro = distance of centroid from centre of wheel

33
K = distance between centre of wheel and line of action of weight

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

2 2

Re cosφ=Fcosθ

W 1+W 2
Re sinφ+ Fsinθ=
2

√
2
2 W 1+W 2
Re = ( Fcosθ) +( −Fsinθ)
2

W 1+W 2−2 Fsinθ

tanφ=
2 Fcosθ

CHAPTER 7

COST ESTIMATION OF THE PROJECT

34
 Table 7.1 Account Statement

ACCOUNT STATEMENT

S.No Item Description Rate Quantity Price

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

2 Ball Bearing Deep groove, 60 each 4 pcs 240

SKF6006
3 S.S. grade304 250mmx900mm 200/kg 3.5kg 700

4 M.S. hollow pipe OD=30,ID=26 - 4m long 200

5 Pipe Bending Costs Handle Pipes 20 each 2 40

6 M.S. plate 300mmx400mm 55/kg 1.7kg 90

7 Pipe and plate cutting costs - 10 per 15 150

cut
8 Plasma arc Cutting - 50 each 4 200

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

10 Material for Shaft & Bearing - - - 170

housings
11 Turning & Facing for Bearings - - - 350
housings & shaft
12 Washer and Cotter pin - - - 20

13 Welding and Finishing costs - - - 1120

Total
4900

CHAPTER 8

DISCUSSION AND CONCLUSION

35
8.1 DISCUSSION

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.

Fig 7.1 Modified Wheel Frame Setup

CONCLUSION

36
 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.

REFERENCES

37
1. Dr. R.K. Bansal, A text book of Strength of Materials, Laxmi Publications (P) Ltd.

2. R.S. Khurmi, J.K. Gupta, A textbook of Machine Design, S.ChandPublishing House

(P) Ltd.

3. www.wikipedia.com

4. www.mit.edu

38