http://www.personal.psu.edu/vum119/edsgn100_su16_section2016_team1_dp1.pdf

EDSGN 100: INTRODUCTION TO ENGINEERING DESIGN Section 204 Team #1

BOX CART

Submitted by: Chang - http://www.personal.psu.edu/cbl5289/

Vinay Murthy - http://www.personal.psu.edu/vum119/ Aidan Fitzpatrick - http://www.personal.psu.edu/aef5343/ Connor Lankay - http://www.personal.psu.edu/cml6126/

Submitted to:

Xinli Wu - http://www.engr.psu.edu/xinli/edsgn100/

Summer 2016

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Abstract

The design for the folding shopping cart is based around a person needing one to carry

their groceries over long distances. It needs to carry all of their groceries and be easy enough for

anyone to use. This design includes two boxes, which can easily fold and be used as stools, and

the base which could also be used as a dolly to carry other materials.

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Table of Contents

Cover Page…………………………………...… Connor Lankay

Abstract………………………………...… ii – Aidan Fitzpatrick

Table of Contents……………………......… iii – Connor Lankay

Introduction……………………………..…… 1 – Vinay Murthy

Description of Design Task……………… 2 – Aidan Fitzpatrick

Design Approach…………………………… 3 – Chang Eun Lee

Final Design & Prototype……………..…… 8 – Connor Lankay

Engineering Analysis……………………... 10 – Chang Eun Lee

Conclusion………………………………..… 11 – Vinay Murthy

Acknowledgement………………...…..……. 12 – Vinay Murthy

References…………………………….....…. 13 – Vinay Murthy

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Introduction

One of the engineering design sections was given the task to create a foldable shopping

cart that met certain specifications given by the instructor, Dr. Xinli Wu. The foldable shopping

cart was required to be easy to use, ideal for transporting groceries and other materials, foldable

for easy storage, no more than $50 to make, and have a weight capacity of one-hundred pounds.

The group of four consisting of Aidan, Chang, Connor, and Vinay worked hard to come up with

the most practical design that met all of the specifications. This report gives an in depth overview

of what this group did every step of the design project.

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Description of Design Task

Problem Statement: The problem is that an individual who does not own a car or does not have a

convenient way of carrying their groceries needs a folding shopping cart to make transporting

groceries a much easier task. The cart must have a weight capacity of 100 pounds, and the

materials must total no more than 50 USD.

Mission Statement: It is our mission to design a working prototype of a folding shopping cart for

people without cars, or for people that don't have a convenient way of carrying their groceries.

We strive to design a durable, safe, and functional product that eases the task of transporting

goods. In addition, this shopping cart will be able to hold up to 100 pounds, which allows the

user to carry a large load of items in one haul. Our design will also be affordable to the common

consumer, as the price will be at around 60 to 80 USD.

Design Specifications: Our design has to be able carry groceries or any other materials that sum

to 100 pounds. It will be covering all sorts of distance, so our design must be able to drive and

not wear down easily. Where we hold the groceries, our boxes, and the base itself have to be able

to fold in a manner that is easy for the user. The materials in which we make our design have to

sum to and not surpass $50. Our design has to be durable, safe, and easy for anyone to use.

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Design Approach

Gantt Chart:

Task Name

Start

Dates

Number of

Days 6/30/16 7/7/16 7/14/16 7/21/16

Identify Needs

Target Specifications 6/30/16 1

Information Gathering 6/30/16 10

Concept Generation and

Selection

Brainstorming 6/30/16 14

Decision Matrix 7/7/16 2

Design Drawings 7/7/16 2

Prototype

Construction 7/14/16 1

Design Evaluation and Testing 7/18/16 1

Present

Project Report 7/21/16 1

Oral Presentation 7/21/16 1 Customer needs assessment:

1. How often do you go shopping at a grocery store? 2. Why would you buy a folding shopping cart?

3. Would you buy a foldable shopping cart if it had another use in the household? 4. How much would you spend on a folding shopping cart? 5. What is an ideal size/weight for a foldable shopping cart?

6. How would you be using this folding shopping cart? 7. What will the distance be that you would have to cover with the folding shopping cart?

8. If you were to buy a foldable shopping cart, how often would you use it? - once a week 9. How long are you expecting to use the foldable shopping cart? 10. In addition to shopping groceries, what else would you like the foldable shopping cart to

be used for? 11. If you were to use a foldable shopping cart, what would be a possible issue/problem?

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Concept generation: Each member of the team came up with at least one design for a foldable

shopping cart. They made drawings and evaluated each idea. From there, the group used design

matrices to determine which design to employ. The final concept was a box made of wood for

sturdiness and longevity. There would be 2 boxes so that it can accommodate more groceries.

The boxes may also be used as a separate container. The folding of the box would be simple and

compact, because of the use of Velcro.

FIG. 1.1. Aidan’s box concept

FIG. 1.2. Connor’s

folding concept

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FIG. 1.3. Connor’s collapsible concept

FIG. 1.6: Chang’s lift concept

FIG. 1.4. Vinay’s

first folding concept

FIG. 1.5. Vinay’s

second folding concept

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Selection Criteria

A Aidan #1

(BOXES)

B Connor

#1 (FOLD)

C Connor #2

(COLLAPSE)

D

(Reference)

Bed, Bath

& Beyond

E Vinay

#1 (FOLD)

F Vinay

#2 (FOLD)

G Chang

#1 (LIFT)

Durability + 0 0 0 0 0 +

Safety 0 0 0 0 0 0 0

Ease of Use + - + 0 - 0 0

Maneuverability - 0 0 0 - 0 0

Capacity + + + 0 - 0 0

Portability - 0 0 0 + 0 +

Scores

Sum +’s 3 1 2 0 1 0 2

Sum 0’s 1 4 4 6 2 6 4

Sum –’s 2 1 0 0 3 0 0

Net Score +1 0 +2 0 -2 0 +2

Rank 3 4 1 4 7 4 1

Continuation? YES NO YES NO NO YES YES

Table 1. First decision matrix

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Table 2. Second decision matrix

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Final Design & Prototype

(made at a 1:4 scale) FIG. 3. Images of prototype

FIG. 2. Mechanical drawing

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Design Features: The final design features two separable boxes that can be used as individual

storage units, stools, or can simply fold flat and be put away. The base of the design doubles as a

dolly that can be used to carry large items that would not fit into a box or would be hard to place

inside. Each box folds to approximately 5/8” thick.

Operation Instructions: To unfold the shopping cart, first lift the smaller top box off of the larger

box. Then, unstrap the Velcro and fold the opposite walls backwards along their adjacent sides.

Place the sides down along the inside of the box. Next, lift the larger bottom box off the base and

set it aside. Unstrap the Velcro straps on the side and fold one wall inward and the other wall

outward. Fold the outward-facing side down along the inside of the box, and fold the inward-

facing side down along the outside of the box. Place each piece back on the dolly and store the

device away for later use. To refold the shopping cart, simply follow these instructions in

reverse.

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Engineering Analysis

Working Mechanism: Our device is intended to fold. The boxes have Velcro on the sides so that

it can attach/detach. The corner braces hold the box in place. Once the bigger box is secured to

the cart, the smaller box can also be attached on top of the box. The user would hold the handle

of the cart and push it around.

Cost Analysis: The total cost of the parts is $46.72. The use of rubber wheels contributed greatly

to the cost-efficiency of the product, and many parts were bought in bulk so that it would be

cheaper to make. Compared to other materials, PVC pipes are significantly cheaper and sturdy.

4’ * 8’ WOOD BOARD: $4.97 /each (2 pieces) = $9.94

1-1/2 in. Zinc-Plated Corner Brace (4-Pack): $2.67 / each (3 4-Packs, 12 total corner brackets) = $8.01

HINGES:

$4.84 for a 10 piece = $4.84

SCREWS FOR HINGES, WOOD, AND WHEELS:

$1.94 for a 20 pack / getting two packs = $3.88

VELCRO TAPE: $4.28

WHEELS: $9.99

PVC PIPE (1” * 10’): $3.80

PVC PIPE ELBOW COUPLER (1”):

$0.98 / each (2) = $1.96

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Conclusion

The final design from this group shows that the objective of this project was met. A

foldable shopping cart was created meeting all of the specifications as well as satisfying the

customer’s needs. Each group member benefitted from this project as everyone acquired skills in

teamwork, project planning, leadership, and using certain lab equipment. Overall, the project was

a success and the group members learned what skills they need to succeed in the real world.

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Acknowledgements

The group is very thankful for Dr. Xinli Wu’s instruction on technical drawing as well as

Penn State for providing the resources necessary to create the prototype. The feedback from the

customers who filled out the customer needs questionnaire was also greatly appreciated as it

helped the group decide what factors to include as part of the criteria.

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References

“Home Depot.” HomeDepot. HomeDepot, n.d. Web. 15 July 2016.

“Amazon.” Amazon. Amazon, n.d. Web. 15 July 2016.

“McMaster-Carr.” McMaster-Carr. McMaster, n.d. Web. 15 July 2016.