Handicapped Steering Cycle Project Report

PROJECT SYNOPSIS
ON
DESIGN AND FABRICATION OF STEERING PROPULSION TRICYCLE FOR
HANDICAPS
Submitted in partial fulfillment of the requirements for the award of
BACHELOR OF TECHNOLOGY
IN
Mechanical Engineering
(2020)
BY
Submitted by:
Under the guidance of
CollegeLogo
College Name
Affiliated to
Dr. A.P.J.ABDUL KALAM TECHNICAL UNIVERSITY, LUCKNOW

DECLARATION
I hereby declare that the project report entitled “Project Name” submitted is our original
work and the report has not formed the basis for the award of any degree, associate ship,
fellowship or any other similar title.
Signature:
Name:
CERTIFICATE
This is to certify that the project report entitled “Project Name” is the bona fide work carried
out by students of “College Name” during the year 2019 in partial fulfillment of the
requirements for the award of the Degree of B. Tech. The report has not formed the basis
for the award previously of any degree, diploma, associate ship, fellowship or any other
similar title.
Signature of the guide:

Date:
ACKNOWLEDGEMENT
It gives me great pleasure to express my gratitude and heart full thanks to all those who are
helping me in complete this project.
I want to thank to “guide name”, who has always encouraged and help me in
making this project. In addition to this, I am grateful to other faculties too who made me in
right direction and gave me their precious time and expert guidance whenever necessary
through which I could achieve this extent.
At last but not the least I am feeling glad to say about my family whose wishes are
always with me, without which it was not possible for me to reach this extent.
I hope my work is praised and my efforts render fruitful result.
THANK YOU
Signature:
Name:
CONTENTS
CHAPTER NO TITLE PAGE NO
1. INTRODUCTION 1
1.1 Introduction to handicap vehicle

1.2 History
1.3 Existing handicap vehicles
1.3.1 Electric powered
1.3.2 Manual wheelchair propulsion
1.3.3 Geared system
1.3.4 Power assists
1.4 Aim of project
1.5 Working principle
2. PROJECT DESIGN 21
2.1 Project layout

2.2 Design of various parts
2.2.1 Seat
2.2.2 Rear support
2.2.3 Front support
2.2.4 Rear axle
2.2.5 Cranking offset flat
2.2.6 Steering ram
2.2.7 Steering actuator
2.2.8 Steering support
2.2.9 Steering column rod
2.2.10 Ball bearing house
2.2.11 Pulley and crank wheel
2.2.12 Caliper mechanism braking
2.2.13 Connecting rod and guide bush
2.2.14 Wheel
2.3 Configurations
3. CALCULATIONS 40
3.1 Mechanical advantage

3.2 The law of lever
3.3 Resistance to the motion of vehicle
3.4 Tractive effort
4.
4.1 Advantages
4.2 Disadvantages
4.3 Applications
5. EXPENDITURE 45
DESIGN AND FABRICATION OF LOW COST TRICYCLE FOR HANDICAPS
USING STEERING COLUMN PROPULSION
Chapter 1
Introduction
1.1 Introduction to handicap vehicle
There are lot of technological advancement, in wheel chair propulsion other than
manual wheel turning. A normal wheel chair used for handicap and the tricycle users for
normal people use hand drive or propulsion or foot pedal propulsion.
The manual propulsion has become increasingly important because the population of
propulsion of individuals using wheelchairs is growing and requires efficient mobility to
maintain a quality of life equivalent to the general population. Several attempts have been
made at improving manual wheel chair propulsion, such as changes in the wheels and tires,
adding gears and designing alternative propulsion systems. Still, experts and consumers
generally agree that innovation in propulsion is still needed. Improved propulsion
technologies will reduce physical fatigue and effort maneuverability. Pain and upper
extremity injury is common among manual wheel chair users. Shoulders related injuries have
been shown to be present in up to 51% of manual wheel chair users. In addition, the
prevalence of elbow, wrist and hand pain has been reported to be 16% . During wheel chair
propulsion, users must exert large forces in order to propel the chair forward. In addition, the
component of force that is directed in towards the hub does not contribute to forward motion
but is necessary in order to provide friction between the hand and the push rim. There are two
popular types of propulsion assist devices on the market today. One is a manual assist that
uses gear rations to reduce the effort required to propel the vehicle and the other is a power
assist that uses a battery powered motor to reduce the effort.
Mechanical advantage is a measure of the force amplification achieved by using a

tool, mechanical device or machine system. Ideally the device preserves the input power and
simply trades off forces against movement to obtain a desired amplification in the output
force. An ideal mechanism transmits power without adding to or subtracting from it. This
means that ideal mechanism does not include a power source, and is frictionless and
constructed from rigid bodies that do not deflect or wear.
1.2 History
AUTOMOBILE ENGG. Page 1

The earliest records of wheeled furniture was an inscription found on a stone slate in China
and a child‘s bed depicted in a frieze on a Greek vase, both dating back to the 6th century.
The first records of wheeled seats being used for transporting the disabled date to three
centuries later in China; the Chinese used their invented wheelbarrow to move people as well
as heavy objects. A distinction between the two functions was not made for another several
hundred years, when images of wheeled chairs made specifically to carry people begin to
occur in Chinese art.
Later dates relate to Europeans using this technology during the German Renaissance.
The invalid carriage or Bath Chair seems to date from around 1760.
Harry Jennings and his disabled friend Herbert Everest, both mechanical engineers, invented
the first lightweight, steel, collapsible wheelchair in 1933. Everest had broken his back in a
mining accident.
Manual wheelchairs are those that require human power to move them. Many manual
wheelchairs can be folded for storage or placement into a vehicle, although modern
wheelchairs are just as likely to be rigid framed.
Manual or self-propelled wheelchairs are propelled by the occupant, usually by turning the
large rear wheels, from 20-24 inches (51–61 cm)in average diameter, and resembling bicycle
wheels. The user moves the chair by pushing on the handrims, which are made of circular
tubing attached to the outside of the large wheels. The handrims have a diameter that is
slightly less than that of the rear wheels. Skilled users can control speed and turning and often
learn to balance the chair on its rear wheels — do a wheelie. The wheelie is not just for show
— a rider who can control the chair in this manner can climb and descend curbs and move
over small obstacles.
Foot propulsion of the wheelchair by the occupant is also common for patients who have
limited hand movement capabilities or simply do not wish to use their hands for propulsion.
Foot propulsion also allows patients to exercise their legs to increase blood flow and limit
further disability.
One-arm drive enables a user to guide and propel a wheelchair from one side. Two handrims,
one smaller than the other, are located on one side of the chair, left or right. On most models
the outer, or smaller rim, is connected to the opposite wheel by a folding axle. When both
handrims are grasped together, the chair may be propelled forward or backward in a straight
line. When either handrim is moved independently, the chair will turn left or right in response

to the handrim used. Another alternative is a Lever Drive chair that propels the chair
forwards by using a lever that is pumped back and forth. [5] Some chairs are also configured
to allow the occupant to propel using one or both feet instead of using the rims.
Attendant-propelled chairs (or transport wheelchairs) are designed to be propelled by an

attendant using the handles, and thus the back wheels are rimless and often smaller. These
chairs are often used as 'transfer chairs' to move a patient when a better alternative is
unavailable, possibly within a hospital, as a temporary option, or in areas where a user's
standard chair is unavailable. These chairs are commonly seen in airports. Special airplane
transfer chairs are available on most airlines, designed to fit narrow airplane aisles and
transfer wheelchair-using passengers to and from their seats on the plane.
Wheelbase chairs are wheeled platforms with specially molded seating systems interfaced
with them for users with a more complicated posture. A molded seating system involves
taking a cast of a person's best achievable seated position and then either carving the shape
from memory foam or forming a plastic mesh around it. This seat is then covered, framed,
and attached to a wheelbase.
Light weight and high cost are related in the manual wheelchairs market. At the low-cost end,
heavy, tubular steel chairs with sling seats and little adaptability dominate. Users may be
temporarily disabled, or using such a chair as a loaner, or simply unable to afford better.
Heavy unmodified manual chairs are common as "loaners" at large facilities such as airports,
amusement parks and shopping centers. In a higher price range, and more commonly used by
persons with long-term disabilities, are major manufacturer lightweight chairs with more
options. The high end of the market contains ultra-light models, extensive seating options and
accessories, all-terrain features, and so forth. Reclining wheelchairs have handbrake-like
controls attached to the push handles or posts supporting the backrest which, when pressed by
the caregiver, allow the backrest to recline from is normal upright position (at 90 degrees) to
varying angles up to 180 degrees.

1.3 Existing handicap vehicles
1.3.1Electric-powered
An electric-powered wheelchair is a wheelchair that is moved via the means of an electric
motor and navigational controls, usually a small joystick mounted on the armrest, rather than
manual power. For users who cannot manage a manual joystick, head switches, chin-operated
joysticks, sip-and-puff or other specialist controls may allow independent operation of the
wheelchair
Other variants
A Standing wheelchair is one that supports the user in a nearly standing position. They can be
used as both a wheelchair and astanding frame, allowing the user to sit or stand in the
wheelchair as they wish. They often go from sitting to standing with a hydraulic pump or
electric-powered assist. Some options are provided with a manual propel model and power
stand, while others have full power, tilt, recline and variations of power stand functions

available as a rehabilitative medical device. [6] The benefits of such device includes, but is not
limited to:
 Raises Independence

 Raises Self Esteem

 Heightens Social Status

 Allows For Easier Communication

 Extends Access Level

 Improved Quality of Life

 Increased Pressure Relief Improved functional reach to enable participation in ADL

 Improved Circulation, Enhance independence and productivity

 Improved Respiration, Maintain vital organ capacity, Reduce occurrence of UTI 

 Improved Flexibility, Maintain boner mineral density, Improve passive range motion

 Improved Ease of Transfer, Reduce abnormal muscle tone and spasticity, pressure sores 

Reduce the pressure sores, skeletal deformities, and psychological well being[6]
A bariatric wheelchair is one designed to support larger weights; most standard chairs are
designed to support no more than 250 lbs. (113 kg) on average.
Pediatric wheelchairs are another available subset of wheelchairs. Hemi wheelchairs have
lower seats which are designed for easy foot propulsion. The decreased seat height also
allows them to be used by children and shorter individuals.
A knee scooter is a related device which may be substituted for a wheelchair when an injury
has occurred to only one leg, below the knee. The patient rests the injured leg on the scooter,
grasps the handlebars, and pushes with the uninjured leg.
A power-assisted wheelchair is a recent development that uses the frame & seating of a
typical manual chair while replacing the standard rear wheels with wheels that have small
battery-powered motors in the hubs. A floating rim design senses the pressure applied by the
users push & activates the motors proportionately. This results in the convenience, small size
& light-weight of a manual chair while providing motorised assistance for rough/uneven
terrain & steep slopes that would otherwise be difficult or impossible to navigate, especially
by those with limited upper-body function.
The aims of research were to compare and contrast any differences between this new
propulsion and a traditional wheelchair and to apply these findings to the practicality of

wheelchair use in terms of: Speed of propulsion- the distance covered in a set time measured
in meters per second (m/s). Energy expenditure- how much energy is used by the body to
propel the required distance, measured in calories. Heart rate (HR) - measuring the body‘s
cardiac response is as an indicator of fitness and training implications, measured in beats per
minute (bpm).
Blood pressure (BP) - to gauge the body‘s hemodynamics changes; blood pressure changes
are to be expected in exercise, but large changes can put the individual at risk. This is
measured in millimeters of mercury (mmHg).
It was hypothesized that the new system would allow faster, more efficient coverage of
distance without any adverse affects on the user whilst maintaining any potential
cardiorespiratory (or fitness) training benefits Method:
Advantages
 Lightweight

 Compact

 Directly responsive to user force on push rims and provide most precise feedback

 Provides propulsion options for users: push the tire, the rim, tire & rim, or one arm drive
technology

 Easily understood and adaptable

 Mechanically simple

 Wide acceptance from users

 Least expensive

 Rim can have several different types of coating (changes look and feel)

 Provides the user a mechanical advantage (through gearing or equivalent)

 Provides less tiresome way of propelling

 The user can go faster and farther (in outdoor use)

 Levers are ergonomically better for the user (less body stress induced by propulsion
forces then for push rim)

 The user stays cleaner when using a lever system

 Steering (for some individuals) can be easier

 Steering can be adapted to one arm drive

 The system is not limited just to large wheels

 Levers can have unlimited configurations (e.g. lever height, angle, shape,


 User's strokes are up and down, improved bio-mechanically

 Adds side to side stability

 Rolling resistance doesn't change

 Simple

 Cheap

 Small


 Requires only one arm to push chair

 The user can control everything through the lever. This may helpful for some people.
Disadvantages--
 Does not have the clutch mechanism.

 May not provide adequate feedback (force/travel distance per stroke) as the user gets
from standard push rim. For example, when the user pushes the rim ¼ cycle, the
wheel rotates through ¼ cycle.
1.3.2 Manual Wheelchair Propulsion

1. Problems with current propulsion systems
Manual wheelchair propulsion has a major impact on social life of the user as it determines to
a great extent the range of environments in which the user can move in. At the same time
many hygienic, safety and security issues are related to manual wheelchair propulsion. There
are several problems associated with the current propulsion system. These are highlighted
below. Most of these problems apply to all types of propulsion systems being used today,
though some of them may be specific to some propulsion system.

A. Common environments that cause difficulty in propelling a manual
wheelchair:
 Soft services, (gravel, sand, grass)


 Carpeting.

 Side walks that are uneven,

 Wintry and wet conditions

 Hills
Note: These environments are especially difficult for persons having the use of one upper
limb.
B. Problems that people experience when propelling a manual wheelchair:
 Backaches

 Hand and finger blisters

 Exhaustion.

 Shoulder, wrist, elbow pain,

 Rotator cuff disease,

 Carpal tunnel syndrome.

 Burning of the hands on the rims

 Dirty clothes,

 Calluses on the hands

 Dirty hands

 Perspiration

 Over heating
C. Safety issues when propelling a manual wheelchair:
 Difficulty in controlling the chair when the user‘s hands slip

 Small sharp objects pack into the wheelchair's tires and can cut the user's hands when
they are propelling the wheelchair

 The wheelchair tends to unbalance rear-ward when propelled

 The wheelchair is difficult to maintain balance when the casters get caught in drains and
potholes

 User‘s hands can be injured when braking with the wheelchair's wheel-lock

 User‘s hands can be injured when braking or stopping the wheelchair

 A wheelchair user's foot could drag on the ground without user knowing it and get injured

 Controlling the manual wheelchair‘s speed up and down inclines or rapid speed changes
on level surfaces is a safety issue.

 Faulty brakes/wheel-locks can cause the wheelchair to roll unexpectedly.
Other Comments:
 If footrests become loose they can drag or catch against objects.

 The lack of push handles can contribute to head injury or whiplash if user tips or falls
backwards.

 Lack of wheelchair visibility to motorists is a safety concern.

 When personal items are hung from the back of the chair, they are difficult to reach, out
of sight and subject to theft.

 Disassembly and lifting of the manual wheelchair into the auto can be a difficult.
1.3.3 GEARED SYSTEMS
1. State of Technology
A gearing system gives the user a mechanical advantage enabling persons with limited
strength (e.g. elderly) to independently propel themselves. Some gearing systems can
accommodate standard hand rims. The ability to self-propel improves the cardiovascular
strength of the user.

Limitations for Current Gear Systems :
 Have few gear ratios

 Gear switching mechanisms are sometimes sloppy

 Some designs add to chair width

 May not provide adequate feedback (force / travel distance per stroke) as the user gets
from standard push rim. For example, when the user pushes the rim ¼ cycle, the wheel
rotates through ¼ cycle. With gearing, the user must somehow understand the force and
distance associated with a ¼ cycle push.

 Adds weight to the wheelchair

 User may be mechanically disadvantaged when traveling long distances due to
mechanical loss in the gearing system and added weight.

 May require better hand and upper limb dexterity than standard push rim.

 Users may not understand the benefits (e.g. improved independence, health, …) of geared
systems

 Wheelchair users have not generally accepted available geared hub systems. (Likely for
some of the reasons listed above.)
The Ideal Technology
The ideal geared technology should:

 Be retrofit-able to a wide range of manual wheelchairs.

 Be able to utilize a lever interface (in addition to or as an alternative to a ―standard‖
push-rim) .

 Weigh 5-7 pounds or less, especially if built into the wheels

 Should not bump up ultra-light chair weight to the standard chair weight category

 Have fail safe mechanism that will restore 1:1 gearing ratio and allow operation as a

―standard‖ manual chair

 The user should be able to ―lock out‖ the gearing mechanism to allow operation as a
standard manual wheelchair

 Not add to the rotational weight of the wheel

 Not make noise, but provide audio feedback (similar to mountain bikes) when shifting
gears

 Gear change might be accomplished with pressure pads (possible mechanism)

 Gear change mechanism should have variety of mounting options

 Gear change mechanism should require low dexterity

 Changing gears should occur simultaneously for both wheels

 Gear system should not hinder independent movement of wheels

 Have a reverse gearing ratio similar to low gear forward, with adjustments

 Be ruggedly designed to allow hill climbing and access to rugged terrain

 Be almost invisible (in other words should perfectly blend with wheelchair aesthetic)

 Be an accessory and not built into the chair

 Switch easily from low gear to high gear

 System should have linear geared system (continuous progressive gearing) [most ideal
case]

 System should have four gears with gear ratios starting at between 1:2 to 2:1 [acceptable
but less ideal case]

 User should be able to shift gears during the propulsion stroke.

 User should not have to stop propelling the wheelchair in order to change gears

 Sense your need and automatically change gears while in motion [most ideal case]

 Have a shifting mechanism (e.g. lever) to change gears [acceptable but less ideal case]

 User should be able to change gears while in motion [less ideal case]

 Gear change should be manual (user selectable) rather than automatic

 Give the user more distance per stroke than a standard manual wheelchair (useful for
active users wanting to cover distance more rapidly)

 Should accommodate those with lesser energy levels as well as the highly active
population

 Requires less (hand) dexterity and ability (grip and upper body strength) than current
manual wheelchair propulsion systems

 Not affect free wheeling

 Be integrated into the push rim and hub

 Accommodate high end (active, full strength) and low end (inactive, minimal strength)
users (gearing system should be universal in this respect)

 Have a stop feature

 Have automatic braking system

 Sense and slow the chair, assisting in stopping the chair once the user applies resistance
(or different pressures) to the rims (braking system)

 Provide no more hazard to the hand than current propulsion methods

 ―Be in‖ standard wheel with quick release

 Work similar to the gearing system in a bicycle

 Be financed with HCFA
3. Barriers and Roadblocks
The gearing system:

 Should not affect quick release wheels

 Not affect folding of the wheelchair

 Should not increase the width of the chair
1.3.4 POWER ASSISTS
1. State of Technology
Power assist systems are perceived to turn a manual wheelchair into a power wheelchair. It
gives the user a choice of using a manual or power chair without transferring between the
chairs. At the same time it is much cheaper than power chair. It reduces the physical strain on
the user and extends the range of environments in which the user can move (e.g. uphill,
rougher terrain etc.). Power assists chairs also help in stopping the wheelchair without
grabbing onto wheels or wheel locks.
Limitations:
 Puts greater limits on manual wheelchair by adding weight and complexity to the manual wheelchair, and increasing the cost Type equation here. 

 The power assist increases overall maintenance

 Power assists are not perceived to be reliable and are perceived to add to the overall
likelihood of malfunction

 The user may become ―stuck‖ when venturing into environments that he or she would
normally not access with a ―standard‖ manual wheelchair

 Issues related to batteries, power source (size, weight, charging etc) comes into picture

 Power assists tend to be noisy and heavy

 Current power assists don‘t fit across a wide range of chair models

 Wheelchairs utilizing a power assist are hard to fold which impedes the portability of the
chair
Development of the Ideal Technology
The ideal power assist should:

 Weigh a maximum of five pounds

 Run for a dollar a day

 Should cost $1000 or less

 Have speeds, which ranges from walking to a running speed of up to 7 mph

 Be safe. It should include power on/off switches that will enable/disable the system

 Have variable mounting capabilities.

 If device fails, it should operate like a MWC

 Have smart controls that would automatically change speeds/gears

 Could be integral (hub/axle design, inner-tube, frame) or removable from the chair. If
removable it should be done easily by the end user (not requiring special tools)

 Be quiet

 Not be damaged by rapid changes in torque demands

 Not be damaged by impact shocks occurring at different speeds of use

 Allow the user to set the ―degree (gain) of‖ the power assist

 Benefit people with motor weakness, motor in-coordination, respiratory compromise,
fragility, paraplegia, shoulder problems, elderly

 Work in all environments, bad weather, good, indoors and out, on motor vehicles

 Work over ramps and on uneven terrain

 Have simple engineering design

 Be durable

 Need low maintenance, easily cleaned

 Assist in stopping

 Be unobtrusive and small in size, not adding to width of chair

 Be portable, easily installed or removed from the chair

 Be lightweight (be lifted easily by a person using one arm)

 Should not interfere with storing or transporting the manual wheelchair

 Have a backup power source that should be readily available (utilizes ―off the shelf‖
battery)

 Be able to run the chair eight hours continuously

 Utilize rechargeable, portable batteries

 Battery should recharge while it is being used (e.g. going downhill)

 Power assist should engage when needed (change of slope or surface), perhaps utilize
some ―smart technology‖ to accomplish this

 While power assist is operating, it should sense the force applied to the push rim and
assist accordingly.

 Have a manual override

 Manual engagement and disengagement is ―easy‖

 Must be fail safe and not interfere with regular manual wheelchair operation.

 Must be retrofit-able to all/many manual wheelchair models

 Use requires same cognitive and motor skills as standard manual

 Control interface needs to be easily reached by user

 Chair should be steered by force to the rims (same as they are steered now)

 System should have variable speed control so that speed can be adjusted to conditions

 Reliable, cost efficient to use, readily available for purchase and affordable for people to
buy

 System should be capable of being financed by same funding sources that currently
purchase manual wheelchairs

 System should be cosmetically pleasing

 Should meet all ISO and ANSI standards and consumer acceptance testing

3. Barriers and Roadblocks
 Size should not interfere with functions of the manual wheelchair -can't extend beyond
the overall width and length of chair

 Five year life of power source

 Device should accommodate ―conventional‖ batteries
Limitations:
 Requires good hand grip

 Pushing the rim creates hygiene issues for the user

 Pushing rims have some safety issues

 Requires use of both upper extremities

 May not be the most bio-mechanically efficient propulsion mechanism

 Can cause over-use of muscles

 Larger wheels get in the way of user transfers

 Limits wheel size choice

 Material of the rim becomes cold in the winter, which increase numbness and affects
arthritis

 Shape and size of rim is not optimal for gripping and propelling

 Some surface coatings on the push rim affects the user's grip

 Push rim materials break down over time
LEVER SYSTEMS
Limitations:
 Low acceptance by users


 Limits the wheelchairs ability to be folded

 Limit access to environments by making the chair higher and wider

 Makes side transfers more difficult for the user

 Requires full arm use in a push/pull effort

 Aesthetically obtrusive

 Awkward to use relative to standard push rim (for most users)

 Not aesthetically pleasing

 Hard to control the direction i.e. changing from forward to backward motion I(and vice
versa) is difficult

 Significantly increases the cost of the chair
ONE ARM DRIVE SYSTEMS
Limitations

 Gives the wheelchair a wide turning radius

 Past attempts to sell showed no market (one manufacturer reported sales of five units a
year)

 Adds significant weight to wheelchair

 The user has difficulty initiating movement

 The user needs to make adjustments to change directions from backward motion to
forward motion and vice versa

 One lever drives do not provide smooth, continuous movement

 Braking the chair while using the drive is difficult

 Body posture suffers from use of one arm, (more toned in one place)

 The user needs the use of a foot for steering

 Chair tracking (steering) is difficult

1.4 Aim of the project
 To design and fabricate the three wheel base chair for the handicap people to be
propelled by the link mechanism converting into cranking, using the advantage of
leverage.

 To design and fabricate the chair with proper balance and distribution of mass and
balance and center of gravity and the steering column which is pivoted and effecting
the link mechanism to crank the wheel shaft for propelling.

 To design and fabricate the steering column, the steering mechanism being operated
and through links controlling the front wheel to effect the proper steering as required
and controlled by hand held steering wheel.
1.5 Working Principle
This is a single seater three wheeled vehicle with front wheels being steered by the
steering column. The steering column has the outer tube which is hinged at the base and the
other side extension of the steering column is pulling and pushing the cranking mechanism of
the rear wheel. The internal rod of the steering column is hinged to the link mechanism to the
front wheel to steer the wheel as the steering handle is being rotated which is held at the top
side of the steering column. The steering column is holding the steering rod within the
bearings. The cranking mechanism is on one of the rear wheel axle. The rear wheels are held
on two different axles. The bearing housing of the rear axles are welded to the frame. The
entire frame is made of mild steel square tube .
 The steering column when pulled or pushed, the steering column pivoted at the base
from a distance. This is termed as a lever that pivots on a fulcrum attached to the fixed
frame. The lever operates by applying force at the steering handle, at distance from
the fulcrum or pivot. As the lever pivots on the fulcrum, points further from this pivot
move faster than points closer to the pivot. The power into and out of the lever must
be the same, so forces applied to points farther from the pivot must be less than when
applied to points closer in.


 If a and b are distances from the fulcrum to points A and B and let the force Fa
applied ot A is the input and the force Fb applied at B is the output, the ratio of the

velocities of points A and B is given by a/b, so we have the ratio of the output force to
the input force, or mechanical advantage is given by

Mechanical advantage
Where – a & b distances from pivot point
M1 & M2 masses
Fa&Fb are forces
 This is the law of the lever which was proven by Archimedes using geometric
reasoning. It shows that if the distance a from the fulcrum to where the input force is

applied (point A) is greater than the distance b from fulcrum to where the output force
is applied (point B), then the lever amplifies the input force
Using the above principle, we are using the steering column as lever to get the
mechanical advantage by using the pivot and use the smaller distance from the fulcrum to
connect the crank link of the wheel to propel the wheel to effect the drive.
 In our project we are getting MECHANICAL ADVANTAGE– 7

Chapter 2 Project design.
2.1 project layout
A) Side view
B) Top view

C) side view
D) top view

E) front wheel
F) rear wheel

2.2 Design of various parts

2.2.1 Seat----This is made out of mild steel cold rolled closed annealed square tube of size
20mm x 20mm cut for the lengths of 520mm---2nos, 460mm—4nos410mm---2nos,
all are cut and straightened by hammering and then corner ground for removing sharp
corners and right angle is made and then welded to each other to make two number of
rectangular frame of size 520mm x 460mm and another frame of size 410mm x
460mm. Both are then ground for the corners and edges for sharp corners and then
hinge bushes are welded as hinges to make the seat rest and the back rest to support
the tilting of the seat.
2.2.2 Rear support-------- This is made out of CRCA (cold rolled and closed annealed)
steel square tube of size 20mm x 20mm cut for the length of 300mm---2nos, 150mm--
-1nos and then flattened by hammering and then corner grinding is done and then all
three are joined, the base as 150mm and the vertical legs as 300mm at both the end of
150mm. This is then welded of the front support to make the main frame of the
vehicle.

2.2.3 Front support---------- This is made out of CRCA (cold rolled and closed annealed)
steel square tube of size 20mm x 20mm cut for the length of 400mm---2nos, 120mm-- -2nos,
130mm---2nos, 210mm----1nos and then flattened by hammering and then corner grinding is
done and then all are joined, the base as 210mm and the vertical
legs as 130mm at both the end of 210mm, again 120mm lengths are joined at both the
ends of 210mm and then vertical legs of 400mm are joined at both the ends as per the
sketch. This is then welded to the rear support of the vehicle
2.2.4 Rear axle------------this is made out of C30 steel cut from the round material of 20mm
for length 355mm---2nos and then turned on lathe machine to make the diameter as
15mm for the length of 320mm and step turned and threaded to suit the M10 standard
nut. It is faced from the opposite side to make the entire length as 350mm. Such two
number of axles are made for this project.

2.2.5 Cranking offset flat------ this is made out of mild steel flat of size 25mm x 5mm
thick being cut for the length of 70mm and flattened by hammering and then marked
for the distance of 60mm from one end and then drilling for the hole diameter of
15mm is done and then welded to the one rear axle. On the hole made, a round pin of
diameter 15mm of length 25mm is welded to create the offset cranking pin.
2.2.6 Steering arm------- this is made out of mild steel flat of size 20mm x 4mm thick
being cut for the length of 500mm---2nos and then flattened by hammering and
then marked for the drill of hole size 8mm at both the ends and then marked for
the bending at 40mm distance at both the ends as per the sketch. Such two
number of arms are made for this project.
2.2.7 Steering actuator------ this is made out of mild steel flat being cut from the
material of 25mm x 5mm thick cut for the length of 150mm---2nos, 200mm---
1nos, and then flatted by hammering and then joined together keeping 200mm as
base and 150mm as verticals at both the ends. 15mm round bar of length 35mm
are taken and welded at both the ends as per the sketch. This is welded to the
steering rod at the base.

2.2.8 Steering support------- this is made out of mild steel tube of size 40mm with
inner diameter as 33mm cut for the length of 480mm and then faced at both the
ends to make the parallel and then this is welded to the bearing housings at both
the ends to form the steering support.
2.2.9 Steering column rod-----------This is made out of C30 steel round bar of
diameter 25mm cut for the length of 875mm and then turned on lathe machine to
make the diameter as 20mm for the entire length of 870mm to suit the ball
bearings of inner diameter 20mm.

2.2.10 Ball bearing house

1 Ball bearing housing for 15mm inner diameter ball bearing--------This is made
out of mild steel round bar of diameter 50mm cut for the length 20mm--9nos and
then turned on lathe machine to make the diameter as 45mm and then drilled for the
diameter 18mm and counter bored for the diameter of 35mm for the depth of 10mm
to suit the ball bearing outside diameter and then faced from the other side to make
the total length as 15mm. Such nine ball bearing housings are made for this project.
2 Ball bearing housing for 20mm inner diameter ball bearing

-----this is made out of mild steel round bar of diameter 55mm cut for the length of
20mm----4nos and then turned on lathe machine to make the diameter as 50mm and
drilled for the size of 22mm and then counter bored for the diameter of 42mm for the
depth of 10mm to suit the ball bearing outside diameter of 42mm. This is then faced
from the opposite side to make the total length of 15mm. Such four number of ball
bearing housings are made for this project.

3 Ball bearing housing for 10mm inner diameter ball bearing------ this is made out of
mild steel round bar of diameter 40mm cut for the length of 20mm----2nos and then
turned on lathe machine to make the diameter as 35mm and drilled for the size of 12mm
and then counter bored for the diameter of 27mm for the depth of 8mm to suit the ball
bearing outside diameter of 27mm. This is then faced from the opposite side to make the
total length of 12mm. Such two number of ball bearing housings are made for this
project.
2.2.10Pulley and crank wheel------This is made out of mild steel round bar cut from the
material of 110mm for the thickness of 12mm and then turned on lathe machine to make the
diameter as 100mm, drilled for the hole of 12mm and grove is made of diameter 95mm of
width 4mm at the distance of 2mm from side to facilitate the fixing of belt for power
generation. This is then faced from the opposite side to make the total thickness as 8mm and
then this is welded on the drive axle.

2.2.11 Caliper mechanism braking--------this is a rim brake in which friction pads are
compressed against the wheel rims, hand operated brake lever, force is applied to
brake levers mounted on the steering wheel, and transmitted via Bowden cables,
which apply pressure to the braking surface, causing friction which slows the
bicycle down.
2.2.13 Connecting rod & guide bush

2.2.14 Wheel
as in the generic definition, a rod that serves to attach a wheel to a bicycle and provides
support for bearings on which the wheel rotates. Also sometimes used to describe suspension
component.
Quick release- a lever and skewer that pass through a hollow axle designed to allow for
installation and removal of the wheel without any tools .
Nut - the axle is threaded and protrudes past the sides of the fork/frame. (often found on
track, fixed gear, single speed, BMX and inexpensive bikes)
bolt - the axle has a hole with threads cut into it and a bolt can be screwed into those threads.
(found on some single speed hubs, CannondaleLeftyhubs)
Thru axle - a long axle, typically 20 mm (110 mm width), [they can be 9 mm (100.33 mm
width) in diameter for durability], onto which the fork/frame clamps (found on most
mountain bike forks).
Female axle - hollow center axle, typically 14, 17, or 20 mm in diameter made of chromoly
and aluminum, with two bolts thread into on either side. [1] This design can be much stronger
than traditional axles, which are commonly only 8 mm, 9 mm, 9.5 mm, or 10 mm in diameter

RIM
The rim is commonly a metal extrusion that is butted into itself to form a hoop,
though may also be a structure of carbon fiber composite, and was historically made of wood.
Some wheels use both an aerodynamic carbon hoop bonded to an aluminum rim on which to
mount conventional bicycle tires.Metallic bicycle rims are now normally made of
aluminiumalloy. Rims designed for use with rim brakes provide a smooth parallel braking
surface, while rims meant for use with disc brakes or hub brakes sometimes lack this surface.
BICYCLE TYRE
A bicycle tyre is one which fits on wheels of

a bicycle, unicycle, tricycle, quadracycle, bicycle trailer, or trailer bike. They may also be
used on wheelchairs and hand cycles, especially for racing. Bicycle tires provide an important
source of suspension, generate the lateral forces necessary for balancing and turning, and
generate the longitudinal forces necessary for propulsion and braking. They are the second
largest source, after air drag, of power consumption on a level road. The modern detachable
pneumatic bicycle tire contributed to the popularity and eventual dominance of the safety
bicycle.
Modern bicycle tires can be classified by several different criteria:
How they attach to the rim: clincher or tubular.
 If and how they hold air: tube, tubeless, or solid.










HUB
A hub is the center part of a bicycle wheel. It consists of an axle, bearings and a hub
shell. The hub shell typically has two machined metal flanges to which spokes can be
attached. Hub shells can be one-piece with press-in cartridge or free bearings or, in the case
of older designs, the flanges may be affixed to a separate hub shell.
A hub rotatably engaged on a rear wheel axle of a multi-speed bicycle, a cone disposed
on each end of the rear wheel axle, a bearing rotatably engaged between one end of the body
and one of the cones, a barrel formed integral on the other end of the body and extended
outward toward the other cone, another bearing rotatably engaged between the barrel and the
other cone, whereby, the bearings are rotatably engaged on the ends of the rear wheel axle
such that the rear wheel axle is stably supported in place.

Brake----------A bicycle brake reduces the speed of a bicycle or prevents it from moving. The
three main types are rim brakes, the caliper brake patented by Browett and Harrison in 1887.
This early version of caliper braking used a rubber block to contact the outside of the small
The spoon brake, or plunger brake was probably the first type of bicycle brake and
precedes the pneumatic tyre.[6] Spoon brakes were used on penny farthings with solid rubber
tyres in the 1800s and continued to be used after the introduction of the pneumatic-tyred
safety bicycle. The spoon brake consists of a pad (often leather) or metal shoe (possibly
rubber faced), which is pressed onto the top of the front tyre. These were almost always rod-
operated by a right-hand lever. In developing countries, a foot-operated form of the spoon
brake sometimes is retrofitted to old rod brake roadsters. It consists of a spring-loaded flap
attached to the back of the fork crown. This is depressed against the front tyre by the rider's
foot.
Perhaps more so than any other form of bicycle brake, the spoon brake is sensitive to road
conditions and increases tyre wear dramatically.
Though made obsolete by the introduction of the duck brake, coaster brake, and rod brake,
spoon brakes continued to be used in the West supplementally on adult bicycles until the

1930s, and on children's bicycles until the 1950s. In the developing world, they were
manufactured until much more recently.
2.3 Configurations
Two front wheel
a Tadpole-type trike manufactured in California during the 1980s
A configuration of two wheels in the front and one wheel at the back presents two advantages
: it has improved aerodynamics, and that it readily enables small lightweight motorcycle
power plant and rear wheel to be used. This approach was used by Messerschmitt kr200 and
by the BMW Isetta. Alternatively, a more conventional front-engine, front wheel drive layout
as is common in four-wheeled cars can be used, with subsequent advantages for transversal
stability (further front location of CG) and traction (two driven wheels instead of one).
For the lowest wind resistance (which increases fuel efficiency), a teardrop shape is desirable.
A teardrop is wide and round at the front, tapering at the back. The three-wheel configuration
allows the two front wheels to create the wide round surface of the vehicle. The single rear
wheel allows the vehicle to taper at the back. This approach is used by the Aptera2 Series. It
is also used byMyers Motors for both its single passenger NmG and upcoming 2-passenger
Duo.

Two rear wheel
Having one wheel in front and two in the rear for power reduces the cost of the steering
mechanism, but greatly decreases lateral stability when cornering while braking.
Lateral stability
The disadvantage of a three-wheel configuration is lateral instability - the car will tip over in
a turn before it will slide. This can be prevented in 3 different ways: - By placing the centre
of massis much closer to the ground. (This is easiest for electric three-wheelers that can lower
the center of mass by placing the heavy battery pack as low as possible) - By placing the
center of the mass closer to place with the 2 wheels. - By increasing the track width is to be
much wider than a similar four-wheel vehicle.
Wheelchairs have been used for several hundred years by people for whom walking is either
difficult or impossible and are propelled by either the user, attendant or electrically. The
‗modern‘ self-propelled wheelchair was first seen in the late 19th century, but since then few
changes have been made other than with the materials used in their manufacture and the basic

design has remained essentially the same. The new propulsion system was designed to
increase the ease, efficiency and speed of propulsion using a lever system.
A wheel chair is a chair with wheels that was invented in the early 5 th century. The device
comes in variations where it is propelled by motors or by the seated occupant turnign the rear
wheels by hand> often there are handles behind the seat for someone else to do the pushing
Kinematic Measurement System

An OPTOTRAK 3020 3D motion analysis system (Northern Digital, Inc., Waterloo, Ontario,
Canada) was used to collect position data of infrared-emitting diode markers placed on the
wheelchair user‘s body. The markers were attached with double-sided sticky tabs to the bony
landmarks on the arm most lateral part of the acromion process, lateral epicondyle,
colcannon, third and fifth metacarpalphalangealjoints , and radial and ulnar styloids.
Marker placement and global coordinate system axis representation.
This system was configured to collect the real-time movement patterns of the entire arm,
head, and torso during propulsion. Two cameras were positioned, facing each other, on either
side of the subjects to capture movement patterns bilaterally. A synchronization pulse from
the OPTOTRAK was used to trigger the start of kinetic and kinematic data collection.
Kinematic data were collected at a 60 Hz sampling frequency and filtered with a 4th order
Butterworth low-pass filter, zero lag, and a 7 Hz cutoff frequency.

The present project with gear mechanism and lever propulsion gives the user a mechanical
advantage enabling person with limited strength (e.g.elderly) to independently propel
themselves. Some gearing systems can accommodate standard hand rims. The ability to self-
propel improves the cardiovascular strength of the user.
Both arm drive systems (lever propulsion for both the hands).
Adds weight to the wheel chair.
Gives the wheel chair a wide turning radius.
The user has difficulty initiating movement.
The user needs to make adjustments to change directions from backward motion to forward
motion and vice versa.
On lever drives do not provide smooth, continuous movement.
Braking the chair while using the drive is difficult.
Chapter 3 calculations
3.1 Mechanical advantage

Mechanical advantage is a measure of the force amplification achieved by using a
tool, mechanical device or a machine system. Ideally, the device preserves the input power
and simply trades off forces against movement to obtain a desired amplification in the output
force. The model for this is the law of the lever. Machine components designed to manage
forces and moment in this way are called mechanisms.an ideal mechanism transmits power
without adding to or subtracting from it .this means the ideal mechanism does not include a
power source , and is frictionless and constructed from rigid bodies that do not deflect or
wear. The performance of a real system relative to this ideal is expressed in terms of
efficiency factors that take into account friction, deformation and wear.
3.2 The law of lever
The lever is a moveable bar that pivots on a fulcrum attached to or positioned on or

across a fixed point .the lever operates by applying forces at different distances from the
fulcrum or pivot
As the lever pivots on the fulcrum, points farther from this pivot move faster than
points closer to the pivot. The power into and out of the lever must be the same. The power is
the product of force and velocity, so forces applied to the points farther from the pivot must
be less than when applied to points closer in.

If a & b are distances from the fulcrum to the points A & B and the force Faapplied to
A is the input force and Fb exerted at B is the output, the ratio of velocities of points A & B is
given by a/b, so the ratio of output force to input force or mechanical advantage is given by
This isthe law of the lever, which was proven by Archimedes using geometric
reasoning. It shows that if the distance ‗a‘ from the fulcrum to where the input force is
applied that is A is greater than the distance ‗b‘ from fulcrum to where the output force is
applied that is B, then the lever amplifies the input force. If the distance from the fulcrum to
the input force is less than from the fulcrum to output force, then the lever reduce the input
force.
Archimedes has been famously attributed with the quotation “give me a place to
stand and with lever I will move the whole world”.
3.3 Resistance to the motion of vehicle
Resistance to the motion of vehicle consisting following 3 resistances
1) Aerodynamic resistance (Ra)

2) Rolling resistance (Rr)
3) Gradient resistance ( Rg)
When vehicle is moving on gradient Total resistance R = Ra + Rr +Rg
When vehicle is moving on flat level road then Rg =0
Total resistance = Ra + Rr
1) Aerodynamic
resistance-Ra= KAV^2

K- co.eff. of aerodynamic resistance (k=0.023 for stream line vehicle )

A – frontal c/s area= 20*20mm^2=0.0004m^2
V- velocity 15km/hr=4.166m/sec
Ra= 0.023*0.0004*4.166^2
= 0.00016 N
2) Rolling resistance
Rr = Kr *W
Kr- rolling resistance constant which depends on type of road surface
and tyre(Kr= 0.0059 for good road &0.18 for sandy roads)
W- weight of vehicle with driver = 100 kg= 1000N
Rr= 0.0059*1000=5.9N for good road

Rr=0.18*1000=180N for sandy road
3) Gradient resistance
Rg= Wsinø
Ø= angle of grade (consider 25˚)
Rg= 1000*sin25
=422.92N
Total resistance= R= Ra+Rr+Rg
=0.00016+5.9+422.92
R = 428.82N ( when vehicle is moving on Gradient)
R=0.00016+5.9
R =5.90016N( when vehicle is moving on flat road)

3.4 Tractive effort
The force available at contact between rear wheel ,tyre and road surface
is known as tractive effort .the ability of rear wheels to transmit this
available tractive force without slipping is known as traction.
Tractive effort = F= Tw/r
r - radius of wheel
Tw- torque available at wheel
If driver applies force of 1 Kg i.e. 10 N we get the torque at the rear

wheel of 10*0.7= 7 N –m ( because M.A= 7)
Tw= 7N-m
r = 350mm= 0.350m
Tractive effort F=Tw /r
= 7 /0 .35= 20N
Comparing the calculations F>R then surplus force is utilized for

propelling the vehicle i.e. for pulling the vehicle or grade climbing.

Chapter 4
4.1 Advantages
1. Adding a power assist unit to a three wheel base chair will increase the weight and
may offset the distribution of mass or balance and center of gravity possible making it
more difficult for the user to propel when power assist is disengaged, the present
innovation eliminates all these and simplify the propulsion.
2. This unit can be used for handicap and normal people also.
3. Individuals who have lower extremity weakness, paralysis, or amputation making
walking unsafe or difficult, patients, can use this propulsion which is easy to operate
and will be not require more effort.
4. This is inexpensive, portable unit, light weight and easy carried or shifted.
5. This becomes a best alternate to powered propulsion or hand push propulsion, which
has good control with less energy expenditure.
6. Here we are using the mechanical advantage of the lever using the fulcrum., which is
amplifying the input to output, using less effort the required drive.
4.2 Dis-advantages
1. The propulsion lever will be swiveling even if you are not propelling it due to self
momentum during the drive, to steer it will be difficult since our hands holding the
steering wheel will also swivel which is not convenient for the user.
2. The direction change or actuation in the front or back has to be practiced by the user
since it will take the direction automatically which cannot be controlled, it can be
controlled by stopping and pushing in that direction and then propelling.

4.3 Applications
1. It can be used in the campus for the drive for the normal persons, to move within the
campus in the smooth road.
2. It is best useful for the small city drive for anybody including the handicap.
3. It can be used for material transportation without using fuel propulsion.
4. It can be used by the handicap for the normal transport and even for the self employed
handicap persons for their daily livelihood.

Expenditure
Main parts involving in this project---------
1. Seat--------------mild steel tubular section---------------1set-------------------Rs. 500

2. Seat with back rest------------------------------------------------1set-------------Rs 200
3. Front fork-------------------------mild steel----------------1set-------------------Rs 300
4. Front wheel axle--------------------C30 steel-------------1set--------------------Rs 400.
5. Wheel rim with tyre tube------------standard----------3nos---------------------Rs 650.
6. Hinge bush for seat ----------mild steel--------------------4nos------------------Rs. 300
7. Connecting rod-------------------C30 steel----------------1nos-------------------Rs. 300
8. Steering column ---------------mild steel-----------------1set--------------------Rs. 250
9. Steering wheel-----------------standard---------------------1set------------------Rs 400.
10. Rear support frame------------mild steel tube-----------1set--------------------Rs. 800
11. Front support frame-----------mild steel tube-----------1set--------------------Rs. 400
12. Rear axle--------------------C30 steel------------------------2nos-----------------Rs. 250
13. Cranking offset assembly-------C30 steel and mild steel---1set---------------Rs. 500
14. Steering arm-----------------------mild steel---------------------2nos-----------Rs. 650
15. Steering actuator-----------------mild steel --------------------1set-------------Rs. 500
16. Steering column rod-------------C30 steel---------------------1nos-------------Rs. 300
17. Steering support-----------------mild steel---------------------1nos-------------Rs. 300
18. Guide bush------------------------mild steel---------------------2nos-------------Rs. 500
19. Bearing housings for 15mm internal dia bearing---mild steel-----7nos------Rs 450
20. Bearing housing for 20mm internal dia bearing---mild steel------4nos------Rs 200.
21. Labour cost--------------------------------------------------------------------------- Rs 150
TOTAL COST--------------------------------------------------------Rs 8300

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PROJECT SYNOPSIS

Under the guidance of

Dr. A.P.J.ABDUL KALAM TECHNICAL UNIVERSITY, LUCKNOW

Signature of the guide:

1.1 Introduction to handicap vehicle

2.1 Project layout

3.1 Mechanical advantage

1.1 Introduction to handicap vehicle

Mechanical advantage is a measure of the force amplification achieved by using a

AUTOMOBILE ENGG. Page 1

AUTOMOBILE ENGG. Page 2

Attendant-propelled chairs (or transport wheelchairs) are designed to be propelled by an

AUTOMOBILE ENGG. Page 3

1.3 Existing handicap vehicles

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AUTOMOBILE ENGG. Page 5

AUTOMOBILE ENGG. Page 6

1.3.2 Manual Wheelchair Propulsion

AUTOMOBILE ENGG. Page 7

 Soft services, (gravel, sand, grass)

B. Problems that people experience when propelling a manual wheelchair:

C. Safety issues when propelling a manual wheelchair:

 Difficulty in controlling the chair when the user‘s hands slip

AUTOMOBILE ENGG. Page 8

1.3.3 GEARED SYSTEMS

AUTOMOBILE ENGG. Page 9

The Ideal Technology

The ideal geared technology should:

AUTOMOBILE ENGG. Page 10

AUTOMOBILE ENGG. Page 11

3. Barriers and Roadblocks

The gearing system:

1.3.4 POWER ASSISTS

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Development of the Ideal Technology

The ideal power assist should:

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3. Barriers and Roadblocks

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ONE ARM DRIVE SYSTEMS

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1.4 Aim of the project

1.5 Working Principle

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Where – a & b distances from pivot point

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 In our project we are getting MECHANICAL ADVANTAGE– 7

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Chapter 2 Project design.

2.1 project layout

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2.2 Design of various parts

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