Design and Fabrication of Stair Climber Trolley

DESIGN AND FABRICATION OF
STAIR CLIMBER TROLLEY

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 trolleys are used to relieve the stress of lifting while
on flat ground; however, these devices usually fail when it comes to
carrying the load over short fleet of stairs.
• In the light of this, the project attempts to design a stair climbing hand cart
which can carry heavy objects up the stairs with less effort compared to
carrying them manually.
• It also endeavors to study the commercial viability and importance of such
a product. Several designs were conceived that would allow a non-industrial
hand trolley to travel over stairs, curbs, or uneven terrain while reducing the
strain on the user.
INTRODUCTION
HANDTROLLEY
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.
STAIR CLIMBER TROLLEY
• 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.
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 Terrastar, a commercially unsuccessful
amphibious military vehicle. A Tri-Star wheel functions as an ordinary
wheel on flat ground, but has the ability to climb automatically when
an impediment to rolling is encountered. This wheel design consists
of three tires, each mounted to a separate shaft.
SELECTION AND FABRICATION OF STAIR CLIMBER
TROLLEY
• MATERIAL SELECTION
• Material selection is a step in the process of designing any
physical object.
• 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.
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.
D.C.GEAR MOTOR
DC Geared Motor, 12V, 100 RPM, Torque up to 2 Kg-cm
This DC Motor with Metal Gear Head is generaly used in various robotics
applicatons , It has following electrical and mechanical specifications.
Specifications: Motor Type : DC with Gear Box, Metal Gears
Base Motor : DC 3000 RPM
Circular 6mm Dia with Internal Hole

Shaft Type :
for coupling, 23 mm shaft Length
Maximum Torque: ~3 Kg-cm at 12V

RPM : 100 RPM at 12V
Weight : 130 Gms
Max Load Current: ~330mA at 12V
D.C.GEAR MOTOR
A DC motor is not the same as a "gear motor" - a "gear motor" may be an AC
or DC motor coupled with a gearbox or transmission. A gear motor adds
mechanical gears to alter the speed/torque of the motor for an application.
Usually such an addition is to reduce speed and increase torque.
BATTERY
• In our project we are using secondary type battery. It is rechargeable type.
A battery is one or more electrochemical cells, which store chemical energy
and make it available as electric current.
• There are two types of batteries, primary (disposable) and secondary
(rechargeable), both of which convert chemical energy to electrical energy.
Primary batteries can only be used once because they use up their
chemicals in an irreversible reaction.
• Secondary batteries can be recharged because the chemical reactions they
use are reversible; they are recharged by running a charging current
through the battery, but in the opposite direction of the discharge current.
• Secondary, also called rechargeable batteries can be charged and
discharged many times before wearing out. After wearing out some
batteries can be recycled.
BATTERY
WHEEL SELECTION
• Wheel material selected – Filled rubber
• Filled rubbers
• In tyre 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.
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.
Straight Wheel Frame

DESIGN CALCULATION
• Design of Shaft
Outer Diameter, D= 25 mm Inner Diameter, d =18 mm Length of the
shaft = 700 mm
Shaft Subjected To Simple Torsional Moment: Shear strength Ʈ = P/A
Assume, load p= 100kg
=100*9.81=981N
Area = (π/4)*(D2-d2) Area =236.2 mm2
SHEAR STRENGTH
Ʈ = 981/236.2 = 4.153N/mm2
Shaft Subjected To Simple Bending Moment
σ = 32*M*D/ (π*(D4-d4)) M = π/16 * Ʈ * ((D4-d4)/D)
= 9312.457 N mm
σ = (32*9312.457*25)/(π*(254-184)
σ = 8.305 N/mm2
For mild steel σ =580N/mm2

Allowable bending moment < permissible bending moment
8.305 N/mm2< 580N/mm2
Design of Chain Drive
1. Selection of transmission ratio

From PSG Design data book pg. 7.74 i = (z2/z1) = (n1/n2)
= 50/30
= 1.5
COST ESTIMATION OF THE PROJECT
ACCOUNT STATEMENT
S.No Itm Description Rate Quantity Price
Rubber Wheels
1 OD=150mm 250 each 6 pcs 4500
Ball earing
Deep groove,
2 60 each 4 pcs 1000
SKF6006
3 S.S. grade304 250mmx900mm 200/kg 3.5kg 700
4 M.S. hollow pipe OD=30,ID=26 - 4m long 800
5 Pipe Bending Costs Handle Pipes 20 each 2 250
6 M.S. plate 300mmx400mm 55/kg 1.7kg 90
10 per
7 Pipe and plate cutting costs - 15 150
cut
8 Plasma arc Cutting - 50 each 4 200
9 M.S. L angle 1inch - 1 120
- - -
10 Material for Shaft & Bearing housings 520
- - -
11 Turning & Facing for Bearings housings & shaft 1200
12 Washer and Cotter pin - - - 20

13 Welding and Finishing costs - - - 2500
14 dc gear motor - - - 2500
Total 14550
CONCLUSION
• 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.
The modified wheel CAD model is shown in figure 7.1.
PHOTOGRAPHY
REFERENCES
• [1] B. Mohammad Osman Tokhi, G. S. Virk, M. A. Hossain “Climbing and Walking Robots”, publish in
Proceedings of the 8th International Conference.
• [2] Helmick.D, Roumeliotis.S, McHenry.M, Matthies.L, “Multisensor, high speed autonomous stair climbing”,
IEEE/RSJ Conference on Intelligent Robots and Systems (IROS), (2002).
• [3] J Lawn, Member, IEEE, and TakakazuIshimatsu , “Modeling of a stair-climbing wheelchair mechanism with
high single step capability Murray”. Ieee Transactions On Neural Systems And Rehabilitation Engineering, Vol.
11, No. 3, September 2003
• [4] K. Narendra Kumar1, SalunkheRohit, M. Gopala Anjaneyulu3, B. Gopi Krishna4 1 Assistant Professor,
2Associate Professor, 3, 4Student, 1, 2, 3, 4Department of Mechanical Engineering, Swarnandhra College of
Engineering and Technology, Narsapur, Andhra Pradesh, India- 534275
• [5] Kyle A. Johnson, William R. Tuck, “The Tri –Wheel: A Novel Wheel-Leg Mobility Concept” IEEE/RSJ
International Conference on Intelligent Robotics and System (IROS) 2015.
• [6] L. Sunil Kumar , V S Sunitha, K Suresh , Udaya S. Kumar , “Design And Fabrication Of Stair Climber
Trolley” , A Project Report At Anand Institute Of Higher Technology Chennai-603 103 Anna University , Chennai-
600 025 , (2014) .
• [7] Md. A. Hossain, Nafis. A.Chowdhury, Rubaiat.I.Linda, “Stair Climbing Vehicle”, Published In International
Journal Of Research Publications In Engineering And Technology (2010).
• [8] Mr. Pratik.H. Rathod, Mr. Ravi.R. Mishra, Mr. Nitin.A. Waghamare, “Stair Climbing Truck”,published In
International Journal of Emerging Trends in Engineering and Development,(2013)
THANKING YOU

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What is the purpose of developing a stair climbing trolley?

What design was used for the wheels of the stair climbing trolley and why?

DESIGN AND FABRICATION OF

STAIR CLIMBER TROLLEY

• The stair-climbing hand truck is designed to reduce liability rather

Circular 6mm Dia with Internal Hole

Maximum Torque: ~3 Kg-cm at 12V

Straight Wheel Frame

For mild steel σ =580N/mm2

1. Selection of transmission ratio

12 Washer and Cotter pin - - - 20

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