Design and Modification of Innovative Motorized Hand...
Transcript of 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
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)
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
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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
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
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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.
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
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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
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
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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
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
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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
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
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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;
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