CHAPTER 1

INTRODUCTION

1.1 BACKGROUND OF THE STUDY

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, 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.
This device is commonly used by a large number of industries to transport physical products.
A typical hand trolley consists of two small wheels located beneath a load-bearing platform; the
hand truck usually has two handles on its support frame. These handles are used to push, pull and
maneuver the device. The handles may extend from the top rear of the frame, or one handle may
curve from the back. An empty hand truck usually stands upright in an L-shape, and products are
usually stacked on top of the platform. When the goods are in place, it is tilted backward so that
the load is balanced between the platform and the support frame. Especially if heavy or fragile
materials are moved, the person operating the truck should return it to an upright position
carefully, to insure nothing falls off the platform. The front of the frame may be squared off for
boxes or curved for drums and barrels. Sometimes, a hand truck also has straps for securing
loose freight during transport. Professional material handlers prefer to use a hand truck when
moving stackable items such as boxes, crates or packages. Heavier items are usually stacked on
the bottom of the hand truck, with lighter objects saved for the top. Hand truck users must be
careful not to stack it so high that their vision is blocked or the load becomes unstable.
Generally, it is safe to load a hand truck to the level of its handles or the top of the frame. The
load is then shifted onto the wheels with a backwards lifting motion. The user can maneuver the
cargo by steering it left, right or forward.

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 Terrasrae, a commercially

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unsuccessful amphibious military vehicle. A Tri-Star wheel functions as an ordinary wheel on
flat ground, but has the ability to climb automatically when an impediment to rolling is
encountered. This wheel design consists of three tires, each mounted to a separate shaft. These
shafts are located at the vertices of an equilateral triangle. These triangular sets of wheels can
negotiate many types of terrain, including sand and mud; they can also allow a vehicle to climb
over small obstructions such as rocks, holes, and stairs. The wheel assembly may be gear-driven,
with two wheels in rolling contact with the ground. The third wheel idles at the top until the
lower front wheel hits an obstruction. The obstruction prevents the lower front wheel from
moving forward but does not affect the motion of the driving axle. This causes the top wheel to
roll forward into position as the new front wheel. This wheel usually lands on top of the
obstruction and allows the rest of the assembly to vault over the obstruction. Tri-Star wheel in
motion is shown in figure 1.

Figure 1 Tri-Star wheel in motion

1.2 STATEMENT OF PROBLEM

The movement of goods from downstairs to upstairs is a matter of great concern especially to the
refrigeration and air-conditioning office. Since they usually transport their external and internal
air-conditions by carrying them to the various floors of the administration and any other
buildings on campus, there is a need to have a hand truck or trolley that can solve this problem.
Therefore, there is a need to construct a three wheel hand truck to help them transport the good
upstairs.

1.3 OBJECTIVES OF THE PROJECT

The main objectives of the project are;

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 1) To design and construct a three wheel manual stair climber hand truck.

2) To construct and test a consumer-grade hand truck capable of climbing stairs.

1.4 PURPOSE OF THE PROJECT

The purpose of this project is toward increasing the self-sufficiency of person’s reliant on
flexibility assistive devices, and to reduce the load on care workers in providing such mobility.

1.5 SIGNIFICANCE OF THE PROJECT

The significance of the project is to develop a mechanism for easy transportation of heavy load
over stairs. The need of such system have raised from day to day requirement in our society.
Using of this vehicle the labor cost can be reduce as well as large amount of load can be transfer
uniformly with less power consumption.

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 CHAPTER 2

LITERATURE REVIEW

2.1 BACKGROUND OF STUDY

Many researchers performed various experimental investigations on stair climbing vehicles such
as trolley, trucks, chair for handicapped person, forks etc. it requires an in depth study of
maximum load acceptable for a cabin and how stress transferred to wheels alignment.

Pratik H. Rathod et al. designed and fabricated a hand truck which climb stair with less effort
which is useful for library, hospital, regular goods carrier etc. the main modification in this truck
where made at wheels using plat surface roller plate attached instead of traditional wheel frame.
The mechanism based on retched arrangement mechanism. The maximum bending moment was
calculated. The inclination of 44 degrees plays a major role which covers more than 90% of all
stairways within this limit.

Md. A. Hussain et al. designed and manufactured a stair climbing vehicle using modified form of
frame arrangement i.e a curved wheel frame which move on rough surface. To address several
technical issues in designing this vehicle its stability and maintain high speed at vehicle wheel
arrangement while climbing stairs. The frame arrangement consists of sun, planetary, idler wheel
which are assembled to the shaft which reduces application of load. However, the steepness of
the stairs is also the important concern of this study. The vehicle has two set of wheels
arrangement and a stand to support its weight when it moves over the flat terrain.

Raj Kishor Kumar et al. investigated on stair climbing functionality is embedded in the design
through its structure and mechanism. The product mainly consists of modules viz. seat, links and
frame. Anthropometric measures are considered in the dimensioning of seat. Focus is laid on
different parameters such as form, functionality, technology and architecture of the product. The
design of the prototype was done using AutoCAD/CADCAM. The physical and focused
prototype indicating the structure and functionality is developed using thermocol material. Here
wheel carriers are made in Fused Deposition Modelling using Acrylo Butadiene Styrene
material. Wheelchair is embedded with some additional features like integrated commode
facility, after gathering costumer requirements from different subjects.

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P. Jey Praveen Raj et al. designed device such as hand trolley used to relieve the stresses of
lifting while on flat ground. However these devices usually fail when it comes to carrying the
load over short fleet to carry heavy objects up the stairs with less effort compared to carrying
them manually. The main objective of the project is to find an efficient and user friendly method
of carrying various objects through stairs using minimum effort from the user and to also provide
a smooth movement while climbing the stair. Under this project we have manufactured a stair
climber with tri lobed wheel frames at both sides of the climber and three wheels on each sides
are used in the tri lobed frame. The wheel assembly is rotated by pushing or dragging the trolley
which will make the wheels to move automatically.

Roshan Alaspure et al. designed and constructed a Stair Climbing Wheel Mechanism which can
be considered as alternate for lifting goods in such a way that it can be climb a stepped path with
its modified wheel structure using manual metal arc welding or stick Welding. An electric
current is used to strike an arc between the base material and consumable electrode rod or stick.
The electrode rod is made of a material that is compatible with the base material being welded
and is covered with a flux that gives off vapors that serve as a shielding gas and provide a layer
of slag, both of which protect the weld area from atmospheric contamination.

P. P. Gondole et al. fabricated a stair climbing hand trolley with proper dimensions of Height 4
feet, Lower frame 38 x 38 cm, Length of each arm of trigonal wheel axial geometry 15 cm,
Diameter of shaft 15 mm. The major components used in the construction process are square bar
cast iron pipe, Round bar shaft of SAE 1030, rubber rest, caster wheels (industrial rubber), iron
plate, long guzzon pin. Mathematical calculations are made to this work to exhibits expected
results and carried load across the stair very easily thus climbing across stairs transportation of
goods very easily.

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 CHAPTER 3

METHODOLOGY

3.1 INTRODUCTION

In this chapter, the methods used for achieving the objectives of the project will be outlined. The
step by step approach will be thoroughly expressed to be able to reach the purpose of the project.
Below is the flow chart for the project;

3.2 THE FLOW CHART FOR THE PROJECT

The flow chart give the researcher the pattern on which the project will be build or developed on.
The conceptual design, the embodiment design, the material selection of the main components,
design calculation and construction of the prototype and testing will be done accordingly.
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Figure 3. 1 the flow chart for the project

3.3 CONCEPTUAL DESIGN

Conceptual design for the project requires a broad survey which suits the type of design chosen
for the work. Many prototypes were already on the market with their own specifications.

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Three main conceptual designs were evaluated and one was chosen due to its design capability.

design 1 design 2

design 3

Figure 3. 2 conceptual design 1, 2, and 3 respectfully

In figure 3.2, design 1 was constructed having two wheel frame reel and front, on each frame
side is connected to three wheels in an angle that allows the trolley to climb the stairs. Although
this kind of design looks similarly to the project being constructed, the ergonomics of it, does not
suit it. This project will be used in the refrigeration department of the Accra Technical University
for transporting air-conditions and accessories over the stair case. Design 2, having the body
frame just as the project being constructed, can only work in a place where there is no stair case.
This design diminish our project. Design 3 was chosen because it serve the purpose and
objectives of the project, and it can be used at any place be he stair case or flat ground.

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3.4 EMBODIMENT DESIGN

After assessing user needs, some design requirements were included, such as hardware and
software parameters, maintainability, availability, and testability. The detailed prototype was
drawn using AutoCAD/CADCAM software.

Figure 3. 3 AutoCAD drawing of the embodiment design

3.5 MATERIAL SELECTION

Material selection process is very important at this stage, since the construction of the prototype
is important. The materials and components needed for the project are; six wheels, Ball Bearing,
Mild Steel Sheet, Square Rod, Angular rod, Washers, two Rear Wheels, and Round pipe.

3.5.1 WHEELS
The wheel is designed to be attached to the trolley to enable its movement. The wheels were
eight in number that is three at each side and two wheel acting as a stand whenever the trolley is
packed.

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 Figure 3. 4 caster wheel

3.5.2 ROLLER BEARING

Rolling bearings support and guide rotating or oscillating machine elements – such as shafts,
axles or wheels – and transfer loads between machine components. They provide high precision
and low friction and therefore enable high rotational speeds while reducing noise, heat, energy
consumption and wear. Two of the roller bearing will be used, one at each end attached to the
angular shaft.

Figure 3. 5 roller bearing

3.5.3 RODS AND PIPE

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The rods for the construction of the prototype includes, the angular rod, the square rod and the
round pipe. They come in different dimensions since it will be used at different parts to form the
frame on which the mild steel sheet will be placed and welded. The pipe will be used as the shaft
for the wheels.

square rod angular rod

round pipe

Figure 3. 6 the square rod, angular rod, and the round pipe

3.6 DESIGN CALCULATION

A. Determination of Basic Dimensions

The basic external dimensions were considered based on literature survey only. But the designed
model has the dimensions which are calculated based on the step size (height and width) where
the constructed model is going to be tested.

 The external diameter of the solid shaft is taken as 25 mm.

 The length of the shaft is 825 mm.
 Two pairs of static frames and a total of six rubber wheels are used.
 The diameter of wheel is taken as 120 mm for suitable dimensions of the stairs which is
about 140-150 mm in height and 300-350 mm in depth.

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  The inter-lobe angle of Tri-Star clamp is assumed as 120˚.
 The distance between the centers of two wheel was taken as 190 mm.
 The distance between two wheel frames is taken as 635 mm.

Design Calculation for Tri- Star Wheel:

Stair-wheels have been designed for traversing stairs with height 14 cm and width 30 cm. To
calculate the length of the tri star plates and minimum and max radius of wheels the following
formulas are used.

Where a = height of stair = 140mm

b = width of stair = 300mm

t = 25mm

Height and width of the stairs is shown in Figure 3.7, Distance between frame center and wheel
center

Designed height is much lower than the allowable height.

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Figure 3. 7 Tri-wheel on stairs calculation

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