design and modification of innovative motorized hand...

International Conference on Science and Engineering for Sustainable Development (ICSESD-2017) (www.jit.org.in)

International Journal of Advanced Engineering, Management and Science (IJAEMS) Special Issue-3

https://dx.doi.org/10.24001/ijaems.icsesd2017.128 ISSN : 2454-1311

www.ijaems.com Page | 97

Design and Modification of Innovative

Motorized Hand Truck

Dr. M. K. Sonpimple1, Sagar D. Shelare2, Anurag N. Raghorte3

1Associate Professor,Department of Mechanical Engineering,Priyadarshini College of Engineering,

Near CRPF campus, Hingna Road,Nagpur- 440019 2Assistant Professor,Department of Mechanical Engineering,Priyadarshini College of Engineering,

Near CRPF campus, Hingna Road,Nagpur- 440019

[email protected] 3Mtech Scholar,Department of Mechanical EngineeringPCE,Nagpur, India

[email protected]

Abstract – Over the time certain principles have been

found to be applicable in the analysis, design. And

operation of material handling systems.All material

handling should be the result of a deliberate plan where

the needs, performance objectives, and functional

specification of the proposed methods are completely

defined at the outset. The principles of material handling'

are listed and explained. Implementing these principles

will result in safer operating conditions, Iowa costs, and

better utilization and performance of material handling

systems,commercial organization, where the goods are

prepared they need to transport their goods from one

place or one station to another. For this purpose, they use

hand trolley or also known as hand truck on which the

load is handled manually from one place to another.

Sometimes, it is difficult with this equipment to transport

or carry the load manually. In this paper, some design

and modification is practically done on the modelled

hand truck. Further, it is been motorized which make it

simplier for the use instead of manual operation. Design

of the model is done in modelling software called Creo

Parametric 2.0 and considering several factors, the

analysis will be done in analysis software called Ansys

14.0.

Key words:Hand truck, trolley, motored wheel,

ANSYS,CREO-PARAMETRIC 2.0.

I. Introduction

The use of powered and non-powered industrial

trucks is subjected to certain hazards that cannot be

completely eliminated by mechanical means. But by the

intelligence practice and common sense, we can optimize

the risks which are to be incorporated. It is therefore

essential to have competent and careful operators,

physically and mentally fit, and thoroughly trained in the

safe operation of the equipment and the handling of the

loads. Overloading, poor maintenance, load instability,

collision with other objects or hurdles are some of the

serious hazards for the model.

Why Should the Workplace Be Improved?

Due to manual handling of the container, it may extrude

workers to several physical problems (e.g., force,

awkward postures, and repetitive motions) that can lead to

major as well as minor injuries, wasted energy and wasted

time. To avoid these problems, the coming demand of

work tasks and the workers’ capabilities can be improved

coming from the organization. In short, changing

workplace by improving benefit workplace by:

i. Reducing or preventing injuries.

ii. Reducing workers’ efforts by decreasing forces in

lifting, handling, pushing and pulling materials.

iii.Increasing productivity, product and service quality

and worker morale.

iv.Lowering costs by reducing or eliminating production

bottlenecks, error rates or rejections, use of medical

services because of musculoskeletal disorders, workers’

compensation claimsand retraining.

What to Look for?

Due to manual handling of the container, it may extrude

workers to several physical problems. If these tasks are

performed repeatedly or over long periods of time, they

can lead to fatigue and injury. The main risk factors or

conditions associated with the development of injuries in

manual material handling tasks include:

1. Awkward postures (e.g., bending, twisting)

2. Repetitive motions (e.g., frequent reaching, lifting,

carrying)

3. Pressure points (e.g., grasping [or contact from] loads,

leaning against parts or surfaces that are hard or have

sharp edges)

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4. Forceful exertions (e.g., carrying or lifting heavy loads)

5. Static postures (e.g., maintaining fixed positions for a

long time)

6. Injuries may include damage to muscles, tendons,

ligaments, nerves, and blood vessels. Injuries of this

type are known as musculoskeletal disorders.

7. Repeated or continual exposure to one or more of these

factors initially may lead to fatigue and discomfort.

Over time, injury to the back, shoulders, hands, wrists,

or other parts of the body may occur.

What do we need – A Hand truck?

A hand truck is an L-shaped moving handcart which is

generally used for moving the box container in

commercial sector as well. It is also known as box cart,

sack truck, trolley or a bag borrows. It is having the

wheels on the base of the cart, handles at one end and a

flat ledge for holding or loading the objects which is to be

transported. Some hand trucks are set with stair climber

wheels. These stair climbers are used to transport objects

from downstairs to upstairs and vice versa. The hand

trucks are fabricated from several materials which

generally include aluminium extrusion, steel tubs or high

impact plastics.

The hand trucks are of various types and can be

classified according to be use and structures. Some are

according to wheel types, some according to stair climber,

some with handle type or some with wheel size. Other

separates to be taken into account by the shape of load

compared with the shape of backrest, e.g., cylindrical

loads should sit on curved backrest.

Hand trucks are sometimes used as luggage carts

by porters in railway stations and skycaps at airports.

Figure 1 FBD of Hand Truck

WEIGHT OF THE MACHINE=40Kg

WEIGHT OF 1OBJECT =110Kg

TOTAL WEIGHT= WEIGHT OF THE

MACHINE+WEIGHT OF THE OBJECT

TOTAL WEIGHT=40+110=150Kg

TOTAL WEIGHT=150*9.81=1500N

DEFLECTION OF THE SPRING(µ)=50mm

RESULTANT SHEAR STRESS(Ϯ)=350

MODULUS OF RIGIDITY(G)=84000N/mm2

STIFNESS OF THE SPRING(K)=

K= =30N/mm

SPRING INDEX (C) =

WHERE, D=MEAN DIAMETER OF COIL

d=WIRE DIAMETER

D=C*d

SHEAR STRESS FACTOR IS GIVEN BY

Ks=1+

Ks=1+ =1.0625

RESULTANT SHEAR STRESS IS GIVEN BY

Ϯ=KS*

350=

d=10mm

D=C*d=80mm

DEFLECTION IS GIVEN BY

µ=

50=

NO.OF ACTIVE COIL(n)=5

ASSUME SQUARE AND GROUND LEVEL

TOTAL NO. OF COIL(n1)=n+2

TOTAL NO. OF COIL(n1)=5+2=7

NOW,

SOLID LENGTH OF SPRING(Ls)=n1*d

Ls=7*6=42mm

18

FREE LENGTH OF SPRING(Lf)=LS+µmax+0.15µmax

Lf=42+50+0.15*50

Lf=99.5mm

PITCH OF THE COIL(P)=

P=

P=16mm








II. Calculation of Bearing

Figure 2 Ball Bearing

Outside diameter(D)=90mm

Bore(d)=30mm

By using this parameter we have find bearing no.

1) Bearing NO. =0406 …… B. D. SHIWLKAR

data book page no.149

From bearing no. we have find load capacity

2) C=33500 from page no.149

3) Assume bearing life

L10=60 million revolution

4) We know that Bearing life

L10= (C/Fe) 3

For 90% reliability kref=1

60= (33500/Fe)3 ×1

Fe=8557N

Equivalent load is 8557N.

5) We know that equivalent load

Fe= (XFmr+YFma) ×k0×kp×kr

For deep groove ball bearing e=0.25

We also known that

E< Fma/Fmr ……….. From data

book page no.149

Select,

Fma/Fmr =0.47

i.e. 0.47>0.25

Hence X=0.56, Y=1.6

8557= (0.56Fmr+1.6×0.47×Fmr)

8557=1.32Fmr

Fmr =6522N

Fma/6522 =0.47

Fma=3065

For mean axial load is 3065N

For 40% time Fr1=6.5KN, Fa=3.1KN at 300rpm for light

shocks.

For 40% time Fr2=6KN, Fa=3KN at 200 rpm for medium

shocks.

T1=0.4×60=24sec

N1=900/60 ×24=120rpm

T2=0.4×60=24sec

N2=200/60 × 24=80rpm

∑N=N1+N2=120+80=200

Fmr= (Fr13×N1+Fr23×N2/N) 1/3 ……………. From page

no.143

= ((6.5×103)3×120+ (6×103)3×0/200)1/3

For axial load (Fa) = (fa1)3*N1+ (fa2)3*N2/∑N) 1/3

= ((3.1×103) ×120+ (3×103)3×80/200)1/3

Fma=3060N

That’s why we select shaft speed approximately 200rpm

We select diameter of shaft is 40mm

We know that

Td=π/16 ×(D) 3×Tmax

For selecting SAE1030 material Sut=527MPA,

Syt=296MPA

Tmax without key =0.18×Sut

0.3×Syt =0.18*527=94.86MPA

0.3*296=88.8MPA

Ϯmax without key=88.8MPA

Ϯmax with key =0.75*88.8=66.6MPA<Ϯinduce

Td=π/16 *(40)3*66.6=836.9N-mm

Therefore we have calculated design power

Pd=2πNTd/60

=2π×200*836.9*103/60 =17.52kw

III. Design of Spur Gear Spur Gear Tooth Stress

Analysis And Stress Reduction

Gears are used for a wide range of industrial applications.

They have varied application starting from textile looms to

aviation industries. They are the most common means of

transmitting power. They change the rate of rotation of

machinery shaft and also the axis of rotation. For high speed

machinery, such as an automobile transmission, they are the

optimal medium for low energy loss and high accuracy. Their

function is to convert input provided by prime mover into an

output with lower speed and corresponding higher torque.

Toothed gears are used to transmit the power with high

velocity ratio. During this phase, they encounter high stress at

the point of contact.








Figure 3 .Spur Gear

20®FULL DEPTH OF SPUR GEAR TRANSMIT

SMOOTH CONTINEOUS LOAD P=10KW

TEETH ON GEAR(Tg)=75

TEETH ON GEAR(Tp)=20

VELOCITY RATIO= =

VELOCITY RATIO=3.75

PINION SPEED(Np)=400RPM

400/Ng=75/20

GEAR SPEED(Ng)=106RPM

POWER REQUIRED TO TRANSMIT LOAD(P)=10KW

DESIGN POWER(Pd)=Pr*Kl

WHERE Kl=1.25 STEADY AND CONTINEOUS DUTY

Pd=10*1.25=12.5KW

FIND TOOTH LOAD

PITCH LINE VELOCITY(Vp)= = m/s

Dp=m* Tp=20*m

Vp= =

VP=0.418m

Now,

Ft=

Ft=

BENDING STRENGTH(FB)=SO*CV*b*Y*m

FOR PINION,

SELECT MATERIAL FORGED CARBON STEEL

SAE1045HEAT TREATED

(SO)P=210Mpa

(SO)g=SELECT MATERIAL CAST STEEL 0.2%

CARBON HEAT TREATED

(SO)g=196Mpa

ASSUMING TRIAL VALUE(CV)=0.3

b=10m Y=modified lewis factor

Y=

YP=

Yg= =0.4467

(SO)P* YP=210*0.3415=71

(SO)g* Yg=196*0.4467=87

PINION IS WEAKER HENCE DESIGN WITH

RESPECT TO PINION

FB=71*0.3*10m*m=213m2

213m2=

m=5mm

CALCULATE DIAMETER OF PINION & GEAR

DP=m* Tp=5*20=1000mm

Dg=m* Tg=5*75=375mm

FT= =

FT=5800N

VP=0.418*5=3m/s

CALCULATE ACTUAL WIDTH

FB=FT

5800=71*0.3*b*5

b=54.46mm

FIND ACTUAL LOAD

FB= SO*CV*b*Y*m=71*0.3*54.46*5

FB=5800N

FIND DYNAMIC LOAD

FD=FT+

FD=5800+

FD=1500N

Figure 3 Isometric View Of Assembly








Figure 4 Meshing

LOADING CONDITION

• STATIC LOAD

• 4414.5 N OF LOAD ACTING ON THE

FRAME

Type Total

Deformation

Equivalent

(von-Mises) Stress

Minimum 0. m 215.52 Pa

Maximum 1.033e-002 m 9.5434e+008 Pa

Table 1 Result at static loading

Figure 5 Deformation for aluminum alloy

Figure 6 Stress for aluminum alloy

Figure 7 Deformation for Titanium alloy








Figure 8 Stress for Titanium Alloy

Density 4620 kg m

^-3

Coefficient of

Thermal Expansion 9.4e-006 C^-1

Specific Heat 522 J kg^-1 C^-1

Thermal Conductivity 21.9 W m^-1 C^-1

Resistivity 1.7e-006 ohm m

Table 1 Specifications

Figure 9 Deformation for Material 3

ANALYSIS OF STINGER

Failure at high load

Figure 10: Stinger

Figure 11 Deformation

Figure 12 Stress

Figure 13 After modification of the frame

ANALYSIS OF SUSPENSION SYSTEM

At static loading condition








Figure 14 Suspension System

Results

Type Total

Deformation

Equivalent

(Von-Mises) Stress

Minimum 33.583 m 26895 Pa

Maximum 33.585 m 2.2695e+008 Pa

Table 1 Result

IV. Conclusion

After performing analytical calculation many outcome

parameters is having very important aspect in terms of

weighing heavy weight. Design of helical spring ,spur

gear and bearing is done. The standard dimension is

obtained for the effective loading conditions. For

effective implementation obstacles must be taken care of

before initiation and should be backed with action plan to

overcome them. This Standard defines the safety

requirements relating to the elements of design, operation,

and maintenance of low lift and high lift powered

industrial trucks controlled by a riding or walking

operator, and intended for use on compacted, improved

surfaces. Dynamic analysis of whole assembly while

running conditions.

References

1. Safety standard for low lift and high lift trucks an

American national standard, industrial truck standards

development foundation, date of issuance: October 7,

2009

2. Non-motorized transport: confronting poverty through

affordable mobility Paul Guitink, Susanne Holste,

jerry Lebo

3. Powered and manpowered industrial trucks b56 series

introduction

4. Improving mobility and access for the off-road rural

poor through intermediate means of transport; Gina

porter, university of Durham;

[email protected]

5. Analysis of power transmission system for ginning

machine with cotton feeder

6. Stress and fatigue of connecting rod in light vehicle

engine; Bin Zheng, Yongqi lie* and Ruixiang liu

School of transportation and vehicle engineering,

Shandong University of technology, Zibo 255049,

China





design and modification of innovative motorized hand...

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