TRIBHUVAN UNIVERSITY INSTITUTE OF ENGINEERING THAPATHALI

CAMPUS

A PROJECT

ON

DESIGN AND FABRICATION OF STAIR CLIMBING ELECTRIC

WHEELCHAIR

SUBMITTED BY:

RUPAK CHAULAGAIN(THA077BAM030)

SABIN TIWARI(THA077BAM031)

SHISHIR K.C. (THA077BAM043)

SUMAN BHATTARAI (THA077BAM046)

SUBMITTED TO:
ER. DEBENDRA BAHADUR RAUT
HEAD OF DEPARTMENT
DEPARTMENT OF AUTOMOBILE AND MECHANICAL ENGINEERING
THAPATHALI CAMPUS
 CHAPTER 1

INTRODUCTION

1.1 Background

An electric stair climbing wheelchair is used in place of manual power to push a

wheelchair where there is need of ascending or descending of wheelchair. For people
who are unable to push a manual wheelchair or who might need to ascend or descend
stairs to do their daily works and to push the wheelchair not only in smooth but also in
rough paths, it is necessary to power the wheelchair. They can also be utilized by those
with problems related to the heart and exhaustion, spinal cord injury, fractures or broken
legs in addition to those with traditional mobility difficulties. Because they provide
mobility, electric wheelchairs have improved the quality of life for a large number of
individuals with physical limitations. For those with physical limitations, motorized
wheelchairs have become an essential tool that increase their mobility, independence,
and quality of life. These wheelchairs are far superior to manual wheelchairs that are
used traditionally, enabling users to get over physical obstacles and engage fully in
society. These stair-climbing wheelchairs have become a vital assistive technology,
enabling increased accessibility and inclusivity for people with mobility disabilities,
thanks to an understanding of the unique needs of physically challenged people.

1.2 The origin of ideas

Patients suffering from serious injuries such as spinal cord injuries, leg fractures, and
other severe conditions often rely on wheelchairs for mobility. While traditional
wheelchairs are useful for transportation, they have significant limitations, such as the
inability to ascend stairs in locations without elevators or lifts. This innovative
wheelchair addresses this issue by allowing users to easily climb stairs without needing
an elevator. Spinal cord injury patients face the major challenge of being unable to walk
or climb stairs like able-bodied individuals.

One of the key advantages of motorized wheelchairs is the increased independence they
offer. Individuals with physical disabilities often rely on others for assistance with
mobility, but motorized wheelchairs enable them to regain control over their
movements. By operating the chair themselves, users gain a sense of autonomy, self-
reliance, and the ability to make their own decisions regarding where they go and what
they do. The stair climbing wheelchair offer a compact and efficient mode of
transportation that is well-suited for commuting and short trips, and can also be used in
departmental and groceries stores for shopping purposes. Electric motorized
wheelchairs offer environmental benefits such as zero emissions, reduced noise
pollution, energy efficiency, renewable energy integration, recycling opportunities, and
minimized fuel dependency. By choosing electric alternatives, individuals can
contribute to a cleaner and more sustainable environment while enjoying the mobility
and independence offered by motorized wheelchairs. Overall, the ideas for the hand-on
bike kit are the result of a combination of desire for innovation in mobility of the
physically disabled people, market demand, technological advancements and
environmental concerns.

1.3 Attempts so far made by others to address the issues

Researchers, engineers, and designers have made numerous efforts to address the
problems related to powered wheelchairs in Nepal. However, many electric wheelchairs
currently available on the market cannot climb stairs, which poses a significant
challenge for individuals who need to ascend or descend on their own. Standard four-
wheeled wheelchair designs have limitations and cannot perform essential routine
tasks, such as stair climbing, sit-to-stand, and stand-to-sit operations. Although these
models are cost-effective, they restrict the user's mobility.

1.4 Issues Yet to be Addressed

Several critical issues still need to be addressed to improve the functionality and
usability of wheelchairs:

1. Accessibility: A significant obstacle for users is the lack of wheelchair accessibility

in many public and private areas, limiting their ability to navigate these spaces
independently. 3

2. Mobility & Maneuverability: Maneuvering in crowded venues, tight spaces and stairs
can be challenging with current wheelchair designs.

3. Comfort and Fit: Poorly fitted wheelchairs can cause discomfort or pressure sores
with prolonged use, affecting the user's overall health and well-being.
4. Cost: High-quality wheelchairs are often expensive, and the cost of maintenance and
upkeep may not be fully covered by insurance.

5. Maintenance: Regular maintenance is necessary to ensure the wheelchair operates

correctly, which can be both time-consuming and costly.

6. Social Stigma: Wheelchair users may face discrimination and social stigma,
impacting their social interactions and quality of life.

7. Transit: Limited access to public transit options can hinder the mobility of wheelchair
users, restricting their ability to travel freely.

8. Integration of Technology: The cost and availability of advanced features, such as

power assistance or smart technology, often restrict access to these beneficial
technologies.

1.5 Problem Statement

According to the Nepal Census of 2078, 2.2% of the country's population is disabled.
Every male in the population is 2.5%, and every female in the population is 2%. 36.75%
of those with disabilities are physically impaired. People with physical disabilities
encounter numerous challenges in their daily lives. Their independence and mobility
are often hindered by accessibility barriers, such as the absence of ramps or elevators
in buildings and public areas. For individuals with disabilities, navigating stairs can
pose significant challenges, further complicating their mobility. Moreover, the lack of
essential facilities in conventional wheelchairs worsen their difficulties.

Additionally, Physically disabled people face numerous challenges in their daily lives,
including limited mobility and dependence on others for assistance. These individuals
often struggle to navigate their surroundings, access essential services, and participate
fully in society. The lack of independence and mobility significantly impacts their
quality of life, limiting their opportunities for social interaction, education,
employment, and recreation. Even though they are disabled they want to support their
family financially by doing certain jobs but they cannot afford the expensive vehicles
and the inability of the traditional electric wheelchairs to travel for longer routes makes
their daily life difficult.

1.6 Research Objective

1.6.1 Main Objective:

The main objective of this project is to “Design and Fabrication of Electric Stair
Climbing wheelchair.”

1.6.2 Specific Objectives:

• To conduct thorough research on current technologies for wheelchairs designed to

climb stairs and gather user requirements.

• To develop detailed 3D model design in SolidWorks.

• To select appropriate materials and construct a functional prototype following design

specifications.

• To examine the mobility through stairs.

1.7 Scope of the work

Electric stair climbing wheelchairs have a wide range of applications in Nepal,

providing better quality of life, increased mobility, and accessibility in difficult
environments. In addition to helping with infrastructure issues, these wheelchairs
improve health and encourage independence and inclusivity. To increase the use of stair
climbing wheelchairs in Nepal, however, issues like cost, accessibility, availability,
infrastructure constraints, and availability of maintenance and repair services must be
resolved. Our electric stair climbing wheelchair is:

1. Eco friendly

2. Affordable

3. Accessible in multiple terrains

4. User friendly

5. Comfortable

1.8 Limitation

• Cost: The expensive nature of motorized wheelchairs is a significant drawback.

Making a motorized wheelchair that is both affordable and dependable can be
challenging, particularly if sophisticated features or parts are required. The overall
quality and functionality of the wheelchair may be affected by cost constraints.
• Short-term evaluation: If the study only assesses the new motorized wheelchair over
a brief period of time, the findings might not adequately take into account potential
long-term consequences or the durability of the design.

• User acceptance and training: Although motorized wheelchairs can greatly increase
mobility, users may require some time and training to become accustomed to using
them. Certain individuals may have physical or mental impairments that prevent 16
them from using the wheelchair safely. User acceptability and training initiatives need
to be considered in order to ensure the project's successful implementation.

• Resources and time constraints: The study may be impacted by resources and time
constraints, which may affect the volume and complexity of data collection and
analysis.
 CHAPTER 2

LITERATURE REVIEW

2.1 Evolution of Wheelchair

The modern wheelchair, which featured a caster wheel at the back and two sizable
wooden wheels up front, was only created in the 18th century. These wheelchairs
required a lot of help to operate, were heavy, and were aesthetically pleasing. Even
though the wheelchairs used by amputees during World War I and the Civil War were
lighter than these, they still weighed close to fifty pounds and prevented them from
being mobile or independent.

The lightweight and useful modern wheelchair was created by paraplegic Herbert
Everest and his engineer friend Harry Jennings. Because it was foldable and composed
of aircraft steel, this wheelchair was both practical and long-lasting. Wheelchairs are
still manufactured by the E&J Company, which the two founded. They were the
company that provided chrome wheelchairs to WWII veterans. Even so, there wasn't
much mobility assistance and the wheelchairs weren't tailored to the user. It wasn't until
wheelchair users started playing sports with their chairs thanks to Sir Ludwig Guttmann
and others that manufacturers started making chairs that were practical, comfortable,
long-lasting, and aesthetically beautiful.

Mobility is made easy and convenient for its users by the wheelchair's several
contemporary avatars. Users can now enjoy life to the fullest and go almost anywhere
they want thanks to inventions like the wheelchair bicycle and stair climbing
wheelchair. Being restricted to a single room or home is no longer the norm for those
who use wheelchairs. Every wheelchair user's life is undoubtedly made easier and better
by these contemporary innovations.

2.2 Evolution of Stair climbing Wheelchair

2.2.1 Top chair

An electric wheelchair with a built-in stair climbing mechanism is called the Top Chair.
For all other reasons, the chair functions as a typical powered wheel chair and has four
wheels for flat terrain.
The owner can put the chair in "step mode" when it gets close to some steps. As a result,
the rails receive the power. The front wheels then retract, putting the rubber tracks on
the ground as the chair approaches the steps backwards. As the wheelchair gets closer
to the first step, the owner keeps driving backwards and raises the wheelchair's rear
wheels, putting the track on the first step. Because the chair has infrared detectors
installed, this occurs automatically. The owner can start the ascent using the controls.
The chair moves the back wheels first, followed by the front wheels, back down when
it detects the top step.

As the owner descends the stairs, they go ahead and place the chair on the first step. He
goes back into "step mode." As previously, the owner shifts the front wheels forward
and drives. The motion stops and the back wheels retract when the chair senses that the
centre of gravity has surpassed the first step nosing. Moving down the back wheels, the
chair senses the bottom of the steps. Selecting the "road switch" causes the front wheels
to resurface, allowing the owner to drive away normally. A single battery charge is
sufficient to cover about 300 steps, and top chair owners enhance its unparalleled ability
to "go up or down a 20 cm high step."

2.2.2 Stair-Max

Lehner Lifttechnik, a German firm, invented the stair-max. The business specializes in
wheelchair users' mobility. In contrast to the others, this device mounts on standard
wheelchairs and allows users to ascend and descend stairs. The design works well.

Similar to the TopChair, the wheelchair and rider are moved up and down stairs using
powered caterpillar tracks. Before attempting any steps, the user must have the tracks
installed. The tracks may be raised or lowered, enabling the user to access the stairs
from the installation location. The user lowers the stair-max and moves rearward
towards the stairs. After that, the wheelchair is lifted. The rails don't have to be installed
straight onto the first step, which is an advantage over the Top Chair. This is as a result
of the stairmax's tilted tracked front design.

Through a control at the front of the mechanism, the user can regulate the motion up
the stairs (or behind the user as they are climbing up the stairs). The wheelchair seat
returns to a level position during the climb, even though the user and wheelchair enter
the mechanism at an inclination. The Top Chair and the motion down the stairs are
comparable. The wheelchair and user can descend the stairs in comfort thanks to the
tracks.
The mechanism's length is partially to blame for this. It crosses two of the stairs'
hypotenuses. This guarantees a continuous and easy ascent and descent of the stairs.

2.2.3 Tri-Wheel Robot

Early on, this design was a favourite. Its employment in the transportation of large cargo
products attests to its usefulness and efficiency. Four pairs of tri-wheels are located on
each corner of the rectangular robot. To maintain the robot's stability, particularly when
climbing stairs, the servo and drive motors are positioned in the center of the
construction. Every tri-wheel is capable of rotating on its central axis. In this manner,
the wheel can grasp and attach to the step, propelling the second wheel over it. The
robot is then propelled forward by the third wheel rotating over the second wheel. For
every step, this procedure is repeated.

This robot has a drawback in spite of its simplicity and ease of use. The size of its
wheels and wheel rotary system determines how well it can climb any flight of stairs.
One obvious drawback is that the robot must be essentially custom-built for the steps
in question.

Tao W, Xu J, Liu T. Electric-powered wheelchair with stair-climbing ability.

International Journal of Advanced Robotic Systems. 2017;14(4).

The purpose of this article was to provide an overview of the EPW-SC development for
the last two decades and to give insight into future trends. A classification of EPW-SCs
was provided based on an analysis of various stair-climbing mechanisms. A summary
of advantages and disadvantages was provided based on the following four aspects:
control method, cost of mechanical manufacture, energy consumption, and adaption to
different stairs. Lastly, common technologies used to maintain stability during stair-
climbing were discussed to give insights into their future direction. Overall, this article
is a summary of the current EPW-SCs and prospective technology based on research
and may be able to provide insight in the development of more applicable and popular
products. As a useful tool both in clinical practice and robot research, EPW-SC has
attracted an increasing amount of attention from the clinicians and researchers since the
1990s. Although a variety of prototypes have been developed successfully, and several
commercial EPW-SCs are available on the market, it is necessary to develop more
preferable devices and promote their usage among elderly populations and persons with
disabilities.

Rashid Ahmed, K., Razack, S. A., Salam, S., Vishnu Prasad, K. V., & Vishnu, C. R.
(2015). Design and fabrication of pneumatically powered wheel chair-stretcher
device. International Journal of Innovative Research in Science, Engineering and
Technology, 4(10).

The purpose of this article was to provide understanding of the various issues regarding
the mobility equipment and introducing a better design will be an asset for the medical
field and a helping hand for disabled individuals. This paper presents the design and
fabrication of pneumatically powered stretcher-chair convertible device with movable
support segments in an attempt to help such patients and caregivers. This helps the
caregiver avoid heavy lifting situations that put their back at risk of injury. The
caregiver can merely shift the patient from a bed on to the device while the device is in
the form of a stretcher. Then the device can be converted into a wheelchair
automatically with a press of a button. This can be done in the reverse direction as well,
when the patients in sitting in the wheel chair can be converted to a stretcher smoothly
for the purpose of diagnosis etc.

Cooper, Rory A., et al. "Performance assessment of a push rim-activated power-assisted

wheelchair control system." IEEE transactions on control systems technology 10.1
(2002).

Wheelchairs are an important form of mobility for people with disabilities. For many
years, there have only been three wheelchair varieties: electric-powered wheelchairs,
scooters and manual wheelchairs. Recently, wheelchairs have been developed that use
a combination of human power and electric power. The human power is delivered by
the arms through the push rims while the electric power is delivered by a battery through
two electric motors. The shared control system for a push rim-activated power-assisted
wheelchair (PAPAW) must account for the human behavior and the interaction with the
device. The PAPAW uses a form of gain scheduling based upon events recorded from
the push rim torque. Select variables from push rim torque curves were significantly
(p<0.05) changed by the control system to achieve the desired results for PAPAW
operation and manual wheelchair propulsion. With the PAPAW, the peak torque was
decreased by more than 50% and the time spent on the rim was almost doubled. In
addition to offering simple control, the PAPAW was able to dramatically lessen upper
extremity strain, which is frequently linked to secondary disabling conditions in manual
wheelchair users.

Lim, S.H.; Ng, P.K. The Design and Development of a Foldable Wheelchair Stretcher.
Inventions 2021, 6, 35.

This study extends a previous research that conceptualized a foldable wheelchair

stretcher (FWS) by furthering its design and development process. The material and
component selections are accounted for in this study. Simulations are done using
different loads to analyses the stress, displacement and safety factor of the stretcher
design. Bending and maximum load analyses are used to inspect possibilities of
deformation. The usability tests evaluated the regular, folding and alternate functions
of the stretcher. The data for tests 1 and 2 are analyzed using t-tests, while test 3 data
are analyzed using an observational checklist. The FWS performed its regular function
significantly slower than the normal stretcher by about 2 s due to its heavier weight. Its
performance can still be considered akin to a regular stretcher’s performance. The
FWS’s folding function performed significantly faster than the normal stretcher due to
its simpler design. The angle increment test could not be executed due to technical
constraints and the wheelchair function is tested without a seated user. However, the
maneuverability of the FWS as a wheelchair was successfully verified. Finally, a cost
analysis concluded that a commercial-ready FWS can be sold at 600 MYR, which is
relatively cheaper compared to its competitors.

Giuseppe Quaglia, Walter Franco, Riccardo Oderio, A motorized wheelchair with stair
climbing ability, Mechanism and Machine Theory, Volume 46, Issue 11,2011

The paper deals with Wheelchair.q, a concept for a stair climbing wheelchair capable
of moving in structured and unstructured environments, climbing over obstacles and
going up and down stairs. The design of the wheelchair, consisting of a frame, a seat
and a four-bar linkage mechanism that connects frame and seat, is presented. The four-
bar linkage moves and rotates the chair to prevent the wheelchair from overturning and
to guarantee a comfortable posture to the passenger during different operations. The
kinematic synthesis of the linkage mechanism is discussed using an algebraic method.
When the wheelchair faces an obstacle such as a step or a stair, it can passively change
locomotion mode, from rolling on wheels to walking on rotating legs, thanks to its self-
adaptive locomotion units. The function of the locomotion unit is described and
modeled using kinematic equations. The locomotion unit requires only one motor, for
both wheeled and legged locomotion. Tests on a scale prototype were conducted in
order to evaluate the effectiveness of this locomotion.

Rajasekar, R., K. P., Prashanth, R., Senthil Kumar, S., & Sivakumar, A. (2013). Design
and fabrication of a staircase-climbing wheelchair. International Journal of Mechanical
Engineering and Robotics Research, 2(2), 320.Commercially available wheelchairs for
amputees often lack the ability to climb staircases. In our project, we designed a
manually operated wheelchair that can maneuver on both flat surfaces and stairs.
Instead of using standard wheels, we utilized a penta-wheel design. The steel rod is
shaped in a pentagonal configuration, with each rod inclined at an angle of 72 degrees
relative to each other. When climbing stairs, one of the wheels, referred to as the idle
wheel, remains in contact with the ground while another wheel engages with the stair.
Motion occurs when the wheelchair is pulled backward towards the staircase. The
primary objective of our project is to provide stability for the wheelchair user by
ensuring a large support base and maintaining a low center of gravity. Our goal is to
make stair-climbing capabilities accessible to middle-class individuals. A significant
drawback of electric-powered stair-climbing wheelchairs is their high cost and weight.
In this project, we aimed to fabricate a low-cost stair-climbing wheelchair that is
affordable for the average middle-class consumer.

Fang, L., Lu, T., Yuan, K., Shen, X., & Li, L. (2011). Design and development of an
electric-powered stair-climbing wheelchair. In Proceedings of the World Congress on
Intelligent Control and Automation (pp. 474–479).

This paper presents a new multifunctional powered wheelchair that utilizes two sets of
hybrid planetary wheels. Each set consists of one powered wheel and two free wheels.
The wheelchair operates in three modes: stair-climbing mode, powered wheelchair
mode, and manual mode. In stair-climbing mode, an assistant can easily control the
wheelchair to ascend and descend stairs. In powered wheelchair mode, the user has
control over the wheelchair's movement through a dedicated controller. For manual
mode, the wheelchair can be conveniently pushed by an assistant. To ensure the user's
safety, a special mechanism driven by an electric linear actuator has been designed.
 CHAPTER 3

RESEARCH METHODOLOGY

3.1 Workflow

Problem Statement

Literature Review

Planning

Market Analysis

Material Selection

Calculation

No
Design

Yes

Fabrication

No
Testing

Yes

Final Assembly and Report

Fig Flowchart for Methodology

3.1.1 Problem statement:

People with physical disabilities deal with a variety of issues on a daily basis, such as
limited mobility and a reliance on outside help. These people frequently find it difficult
to get around, obtain necessities, and engage completely in society. The motorized
wheelchair provides a convenient and effective means of transportation for individuals
with disabilities. It can be utilized for jobs such as product delivery, which generates
revenue for the user. It is mainly based on supporting the disabled people to perform
specific task like stairs climb which is most difficult part of a wheelchair.

3.1.2 Literature Review:

Reports, articles, and books were studied in addition to conducting web-based research
for this review. We looked at the current state of motorized wheelchairs as well as their
history during this process. Additionally, a review of the literature on motorized
wheelchairs, their operation, and the parts they involve was published with the aid of
books, articles, and reports. Planning: It entails choosing the workshop, allocating
funds, organizing the project's execution.

3.1.3 Planning

It includes organizing how the project will be carried out. First of all we assigned
different works related to the research to all four members. We planned about the cost
analysis of our project , choosing the right materials and design.

3.1.4 Market analysis: This includes, among other things, conducting market research
on the resources that are available for use, their costs, and their effects. It indicates if
the items should be bought or manufactured. In the end, it involves obtaining these
kinds resources.

3.1.5 Material selection: The materials' strength, cost, and availability will all be taken
into account. For our project, we've decided to use structural steel for the frame.

3.1.6 Design and modelling analysis: SOLIDWORKS will be used to 3D model the
chassis frame, and ANSYS will be used to compute the stress, safety factor, and
deformation in structure.

3.1.7 Calculations: The choice of the motor, battery, controller, suspension, brakes,
bearings, and wheels will be determined through the application of empirical formulas.
3.2 Fabrication and Assembly:

Fabrication part will be carried out in the workshop section outside the college. Various
methods will be carried out which are mentioned below:

3.2.1 Arc welding

Arc welding is a technique for joining metal parts by melting them together using an
electric arc to produce extremely high heat, usually above 3,000°C. With either
alternating current (AC) or direct current (DC) as the power source, an arc is formed
between an electrode and the workpiece. Following their fusion, the metals solidify to
create a robust joint.

Fig Arc welding

3.2.2 Drilling

The machining process of drilling uses a revolving cutting tool known as a drill bit
to make round holes in a workpiece. Utilised extensively in sectors including
construction, automotive, and aerospace, it is one of the most prevalent
manufacturing techniques.

⦁ Machining

⦁ Grinding