Load Propelling Trolley Design Report

EMD112 CONCEPTUAL DESIGN AND CAD
LOAD PROPELING TROLLEY

Group B4

Group members:
Wong Pooi Mun 120430
Mark Selvan a/l Anthony Rogers Louis 120385
Faiz bin Mohamad 120367
Muhammad Azizi bin Yahaya 120397
Jerome Lee Jie Jen 120375

Lecturers:
Dr. Abdullah Aziz
Dr Muhammad Iftishah Ramdan
En. Azizul Abd Karim
Dr. Mohd Azmi Ismail

Date of submission:
20 MAY 2014
EMD 112 GROUP B4 2014

2

ABSTRACT
Ubiquitous wheelbarrows require force to be lifted up when wheeled around and
unloading. This simple action takes out energy of construction workers and tires them out.
Another sub-problem for wheelbarrows is the limited volume of their carrying receptacle due
to the inclined surface. Limited volume sets a higher number of travelling back and forth to
move the same amount of load compared to a spacious receptacle.
To those problems, we propose our design Load Propelling Trolley.
Load Propelling Trolley mainly targets society of construction workers as
replacement for wheelbarrow. This trolley eases load-removing process by using lesser
physical strength. This design combines the concept of a wheelbarrow with a door installed in
front for load to be removed. The floor of receptacle shall be inclined for unloading process
and returns to horizontal after that. This horizontal floor allows larger volume in the trolley so
that more loads can be contented, saving time and energy during transportation.
According to the functional decomposition diagram we have constructed, the main
function of a wheelbarrow is to carry load for near-distance transportation. Revolving about
the efficiency of this function, we have inserted certain sub functions for this improvement.
One of them is to enable steering system so that this Load Propelling Trolley can move load
in more directions and with smaller turning radius. Next, we have increased the load capacity
of the carrying receptacle allowing more load to be carried in one time. Another sub-function
that we have focused on is to reduce physical energy consumption in moving and unloading
the trolley. Innovatively, we have eliminated the lifting action that is normally needed in
moving and unloading a wheelbarrow. Load can be propelled off the vehicle instead of being
poured out. And then, for the comfort of the users, we have improved the gripping of the
handle. Slipping effect shall be prevented when it is used to push heavy load.
Several alternatives are available in designing this vehicle. Our team chooses a
latching system to open and close the front door while the floor of the trolley will be inclined
using pivot mechanism. With that, the load will be propelled out of the carrying receptacle
induced by gravitation pull. In this project, we investigate the geometry of the system and the
calculations needed for these mechanisms.
In conclusion, Load Propelling Trolley will benefit workers in construction field by
negating the problem posed by high physical strength required in lifting. With this design,
lesser physical energy can be used for higher workload and efficiency of the workers can be
improved by the increased volume of the carrying receptacle.


3

CONTENTS
ABSTRACT ................................................................................................................................................ 2
Contents .................................................................................................................................................. 3
1.0 INTRODUCTION ........................................................................................................................... 5
2.1 DESIGN PROBLEM ................................................................................................................... 5
2.2 PROBLEM STATEMENT ............................................................................................................ 6
2.3 OBJECTIVE ............................................................................................................................... 6
2.0 METHODOLOGY .......................................................................................................................... 7
3.0 FORMULATING DESIGN PROBLEM .............................................................................................. 8
3.1 FUNCTIONAL DECOMPOSITION DIAGRAM ............................................................................. 8
3.2 FUNCTIONAL REQUIREMENTS ................................................................................................ 9
3.3 ALTERNATIVES ....................................................................................................................... 10
3.3.1 PATENT SEARCH ........................................................................................................... 10
3.3.2 MORPHOLOGY CHART.................................................................................................. 12
3.2.3 MORPHOLOGY MATRIX ................................................................................................. 12
3.2.4 ALTERNATIVE DESIGN SKETCH ...................................................................................... 13
3.3 MATERIAL SELECTION ........................................................................................................... 14
3.3.1 SCREENING METHOD .................................................................................................... 14
3.3.2 RANKING/RATING METHOD ......................................................................................... 14
3.3.3 COMPONENTS ............................................................................................................... 14
3.4 CONFIGURATION DESIGN ..................................................................................................... 17
3.4.1 PRODUCT ARCHITECTURE ............................................................................................. 17
3.4.2 PART CONFIGURATION ................................................................................................. 18
3.4.3 ANALYSING AND REFINING CONFIGURATION ALTERNATIVES ..................................... 19
3.4.4 REFINING ALTERNATIVE CONFIGURATION ................................................................... 21
3.4.5 EVALUATING ALTERNATIVES ......................................................................................... 21
3.5 PARAMETRIC DESIGN ........................................................................................................... 21
3.5.1 DESIGN VARIABLE VALUES ............................................................................................ 21
3.5.2 MANUFACTURING PROCESSES ..................................................................................... 22
3.5.3 PERFORMANCE PREDICTION ......................................................................................... 22
3.5.4 DIMENSIONS ................................................................................................................. 23
4.0 SELECTED DESIGN ..................................................................................................................... 23
4.1 OVERVIEW ............................................................................................................................. 23
4.2 DETAIL DESIGN ...................................................................................................................... 23

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4.3 PRODUCT SPECIFICATIONS ................................................................................................... 24
4.4 DETAIL DESIGN CONSIDERATIONS ....................................................................................... 24
5.0 CONCLUSION ............................................................................................................................. 25
6.0 REFERENCE ................................................................................................................................ 25
7.0 APPENDIX .................................................................................................................................. 27


5

1.0 INTRODUCTION
Wheelbarrows were first invented by the Chinese to transport supplies to war. The
design initially only took advantage of a wheel and lever system, sometimes includes a sail to
reduce original force needed to transport the load.
Being a second-class lever, carrying the load still require an amount of energy in
lifting. This technology is only effective when the load is being put in the right spot. If the
load is placed too far behind, lifting the wheelbarrow to move might be back-breaking. And
so, a wheelbarrow fails to support heavy load. To make it worst, most wheelbarrows only
have a single wheel that makes balancing difficult when handled.
In our project, the team aims to design a trolley to overcome this lifting action.
Although with the current development of load-carrying hand vehicles, ways to lift the load
off the receptacle has been greatly eased by mechanisms, the lifting action still exists. With
the idea of a door at the receptacle and an inclinable receptacle floor, our team has
brainstormed a few alternatives to be evaluated after predicting performance of each concept
design. By following the overall design process as below, we finally select the best design
alternative to proceed with our idea.

2.1 DESIGN PROBLEM

Figure 1 Product A
Steel
Steel Wheelbarrow

Figure 2 Product B
Plastic
Poly Wheelbarrow with Dual
Wheels

Figure 3 Product C
Heavy Duty Poly Dump
Cart

Problem faced by product A:
Single wheel of left product makes balancing difficult when handled.
Wheels located at the front require balancing of load when pushing.
Lifting action consume excessive energy in unloading.
Inclined floor of receptacle limits the shape of load (ie: brick-shaped loads).
Formulation
Concept
Design
Configuration
Design
Parametric
Design
Detail Design

6

Smooth floor of receptacle combined with the inclined shape concentrates the load to
the front of the wheelbarrow causes load to spill easily.
Handle is fixed at a certain angle which might not fit all users comfortability.
Problem faced by product B:
Single wheel of left product makes balancing difficult when handled.
Wheels located at the front require balancing of load when pushing.
Need large turning radius in steering.
Small angle of inclination of receptacle requires large degree of lifting to unload from
carrying receptacle.
Problem faced by product B:
The carrying receptacle is shallow which can only hold limited load.
Need large turning radius in steering. Wheels are not rotate sideways.
Small angle of inclination of receptacle requires large degree of lifting to unload from
carrying receptacle.

2.2 PROBLEM STATEMENT
Wheelbarrows are used to ease transporting loads in short distance and are most widely used
by construction workers. However, the ubiquitous wheelbarrows require to be lifted off the
rear wheel support using force during pushing and unloading process and tires out workers.
When that happens, work efficiency of construction will drop. While the period of
completion is delayed, construction companies will have to face higher expenses which will
in the end effect housing prices.
Therefore, a wheelbarrow which increases work efficiency will be designed.
The project team will design a trolley to replace the function of wheelbarrow. This
trolley will unload by sliding off the receptacle without lifting action; and have a carrying
receptacle with larger volume that comes in a geometry which allows more load capacity.

2.3 OBJECTIVE
To shorten period of construction.
To increase safety factor when transporting load.
To design an inclinable carrying receptacle.
Unloading will be by sliding motion. By that, construction site workers can conserve
energy from the eliminated lifting action to do more work.
To increase volume content of carrying receptacle.
When the construction site worker can transport more loads at a time, time to
complete transporting a large amount of load is decreased.

7

To improve steering motion.
Construction sites are full of obstacles. An improved steering system can reduce
chances of colliding with obstacles.

2.0 METHODOLOGY
Our team has implemented the basic design concept:

Function
Collect and analyze costumer functional requirements and engineering characteristics.
From current products of wheelbarrows used in construction sites, our team analyzed
its strenghs and weakneses as a benchmark for further improvement in our product.
Design
Original concept of ubiquitous wheelbarrow is used as reference. From there we
created alternatives of modifications for each aspect of components and transform our
trolley to make its functions that terms with our objectives.
Alternative designs were drafted and the best selected based on the 'Decision Making
Process'.
Form
Our product, Load Propelling Trolley takes a modified shape of a wheelbarrow to meet
the objectives.
The final configuration of our product will be more complicated but allow higher
efficiency proving its worth.
The dimension of the trolley shall remain almost the same as a ubiquitous wheelbarrow.
The materials used shall be choosen for higher strength, higher maintainance durability
and have reasonable cost.

8

In the engineering design process, our team follows the decision making process:

3.0 FORMULATING DESIGN PROBLEM
3.1 FUNCTIONAL DECOMPOSITION DIAGRAM

Figure 4 Functional Decomposition Diagram for Load Propelling Trolley

F
o
r
m
u
l
a
t
i
n
g

P
r
o
b
l
e
m

Functional
requirements
were
established by
analyzing
strength and
weaknesses of
current
products and
patents.

The design
constrains
were also
identified and
brainstormed
using the
House of
Quality.

Project
objectives
were set.
G
e
n
e
r
a
t
i
n
g

A
l
t
e
r
n
a
t
i
v
e
s

Several
alternative
forms that met
the
requirements
and objectives
were drafted.

A
n
a
l
y
z
i
n
g

A
l
t
e
r
n
a
t
i
v
e
s

The drafted
feasible
alternatives
were analyzed
on suitability
and
performances
based on
logical
estimations.

Feasible
alternatives
were selected
through
elimination
process.

E
v
a
l
u
a
t
i
n
g

A
l
t
e
r
n
a
t
i
v
e
s

Alternative
designs were
compared
using the
Pugh's
Modified
Method and
Weighted
Rating
Method.

Best
alternative
design was
selected.
CARRY LOAD
MOVE LOAD
ENABLE
STEERING
INCREASE LOAD
CAPACITY
PROVIDE MORE
SPACE FOR LOAD
CARRY HEAVY
LOAD
REDUCE ENERGY
CONSUMPTION
ELIMINATE
LIFTING
PROPEL LOAD
EASILY
IMPROVE GRIP

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3.2 FUNCTIONAL REQUIREMENTS
Customer Requirements - Easy to move
- Easy to remove load
- Handle is not slippery
- Able to carry large volume of load
- Able to carry heavy load
- Cost efficient
- Maintenance
- Safety
- No slipping effect on wheels
- Strong materials

Engineering Characteristics - Weight
- Centre of gravity
- Degree of inclination
- Moment
- Force required for inclination
- Friction factor of carrying receptacle
- Volume of carrying receptacle
- Friction factor of wheels
- Corrosion resistance
- Strength of material

Figure 5 House of Quality

10

On referral to the HOQ, the relationships between customer requirements and engineering
characteristics are detailed. For example, a heavy wheelbarrow increases the friction factor of
the wheels which makes it less likely to slide, easier to move, provided the shaft of the
wheels are not pressed more tightly onto the tires.

3.3 ALTERNATIVES
3.3.1 PATENT SEARCH
Patent search can be carried out before designing alternatives to study the weakness
and strength of similar product. Understanding the design selected for patents helps
narrowing the possible alternatives in our design concept. This stage also minimizes impact
of patent infringement.

1) US PATENT NO: US6193319 B1

US PATENT NAME: Handle-propelled, load-carrying land vehicle

DRAWING :

DESCRIPTION:
A handle-propelled, load-carrying land
vehicle comprises a frame having two parts,
one having wheels and ground-engaging
pedestals forward of the wheels, and the other
being pivoted to the front of the first part and
having a load-carrying receptacle mounted on
it and having a telescoping handle.

STRENGTH:
Dumping hand cart for granular loads, since
the forward edge of the receptacle is spaced
from the ground at least at the completion of
the dumping operation.

WEAKNESS:
The force required to tip the receptacle
forward is somewhat larger than the force
required to raise the pedestals off the ground.

2) US PATENT NO: US4789171 A

US PATENT NAME: MULTIPURPOSE BARROW VEHICLES

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DRAWING :

DESCRIPTION:
Two-wheeled convertible barrow vehicle
used as a trailer hitched to a power-operated
vehicle.

STRENGTH:
Can be easily stored and unloading process
more faster

WEAKNESS:
Heavy weight, small amount of load, not
efficient in rough surface

3) US PATENT NO: US5149116 A

US PATENT NAME: BALANCED MULTI-WHEEL WHEELBARROW

DRAWING:

DESCRIPTION:
A wheelbarrow comprising a frame having
two arms defining handles, supporting legs,
a load container and double wheel support
structure. The center of gravity of the
container is located substantially in vertical
alignment with the axle in the operative
position of the wheelbarrow.

STRENGTH:
Adaptable to all kinds of ground or terrain
since it may be equipped with different
wheel arrangements with the wheels
positioned for easy discharge, light weight.

WEAKNESS:
Hard to carry and move because the handle
is not ergonomic towards hand shape.


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3.3.2 MORPHOLOGY CHART

3.2.3 MORPHOLOGY MATRIX
72 alternative designs were formed by all possible combinations of the alternatives in
Morphological Chart.

In the end, 3 alternative designs are chosen, namely alternative 1, alternative 36 and
alternative 69.

Sub-function Alternative Concepts
1

2 3
Inclination system of
receptacle

Lever

Hydraulic cylinder

Pulley
Handle type

Continuous

T-shaped

Projected two arms
Receptacle Floor
Orientation
Horizontal Tray Slanted Tray
Wheel type

Trolley Wheels

Treaded Wheels

Unloading path With door No door

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ALTERNATIVE INCLINATION
SYSTEM OF
RECEPTACLE
HANDLE
TYPE
RECEPTACLE
FLOOR
ORIENTATION
WHEEL
TYPE
UNLOADING
PATH
1 LEVER CONTINUOUS HORIZONTAL
TRAY
TROLLEY
WHEELS
WITH DOOR
36 HYDRAULIC
CYCLINDER
T-SHAPED HORIZONTAL
TRAY
THREADED
WHEELS
NO DOOR
69 PULLEY PROJECTED
TWO ARMS
SLANTED
TRAY
TROLLEY
WHEELS
WITH DOOR

3.2.3.1 WEIGHTED RATING EVALUATION
Concept Alternatives
Alternative 1 Alternative 36 Alternative 69
Criteria Importance
Weight (%)
Rating Weighted
Rating
Rating Weighted
Rating
Rating Weighted
Rating
High Efficiency 40 4 160 2 80 1 40
High reliability 20 3 60 3 60 3 60
Low Maintenance 10 2 20 1 10 3 30
Low Cost 10 3 30 0 0 2 20
Low Energy
Consumption
20 4 80 4 80 1 20
Total 100 16 350 10 230 10 170

Note
Rating Value
Unsatisfactory 0
Just tolerate 1
Adequate 2
Good 3
Very Good 4

3.2.4 ALTERNATIVE DESIGN SKETCH

Alternative 1

Alternative 36


14

Alternative 69

3.3 MATERIAL SELECTION
3.3.1 SCREENING METHOD
Firstly, we screen out materials that are not required in material selection. Furthermore, we
also figure out whether the materials are functional or non-functional and manufacturable or
not. We use two aspects for this case:
Material-first approach
Process-first approach
3.3.2 RANKING/RATING METHOD
For this project, our group decided to use ranking method together with material first
approach.
We screen out materials that will not satisfy the functional requirements of the part. We will
include the criteria regarding the nature of the applied loads and the operating environment.
This screening will eliminate a number of infeasible material classes. Then we rate the
material before we apply it that is we select the best material among those materials which we
have screened out component
3.3.3 COMPONENTS
Handle

Operating Environment
Gripped. Provide support and skin-friendly to user under high load.
Ergonomically shaped.
Suggested Materials
High Density Polyethylene (HDPE) - HDPE commonly have
tensile strengths of between 21.3 and 37.9 MPa. No corrosion. Easy
manufacturing. Flexible.
Bright Oak Bright oak wood has high compressive strength
between 47 to 61.2 MPa and bending strength of 100 to 130 MPa. It
has low density 660 kg/m
3
. And this type of wood has relatively
high tensile strength 163 MPa.
Material of choice

15

Bright Oak
J ustification for choice
Bright oak has lower density than HDPE. Easy to be
manufactured by bending. Able to withstand high stress.

Carrying
receptacle
Floor
Floor Stand
Door

Shifting materials such as: rocks, bricks, sand, tiles, pavers and
concrete.
Suggested Materials
High Density Polyethylene (HDPE) - HDPE commonly have
tensile strengths of between 21.3 and 37.9 MPa. No corrosion. Easy
manufacturing. Flexible.
Medium carbon-steel - Harder than iron. Case hardened steel is
also considered since it makes the steel more water resistant making
it more rust resistant. It is also ductile which is suitable for the
environment the load-propelling trolley will be used.
Material of choice
High Density Polyethylene (HDPE)
HDPE is cheaper than steel. Tensile strength is high enough to
avoid fracture within maximum load capacity. Lower density
than steel, making the product lighter, easier to be handled. Low
static and kinematic friction coefficient.

Lock
Stopper
Shaft
Bracket

Shifting materials such as: rocks, bricks, sand, tiles, pavers and
concrete.
Suggested Materials
Aluminium - Aluminium alloys commonly have tensile strengths
of between 70 and 700 MPa. Unlike most steel grades, aluminium
does not become brittle at low temperatures. Excellent corrosion
resistance. Easy jointing. Aluminiums superior malleability is
essential for extrusion.
Medium carbon-steel - Harder than iron. Case hardened steel is
also considered since it makes the steel more water resistant making
it more rust resistant. It is also ductile which is suitable for the
environment the load-propelling trolley will be used.

16

Material of choice
Medium carbon-steel
Steel is affordable, do not resemble its component elements of
carbon and iron, low in weight, durable, good impact strength,
the ability to cool down quickly from a high temperature when
exposed to water or oil, steel does not rust very easily on
exposure to water and moisture.

Bolts
Nuts
Wet, muddy, constant force subjection, poor maintenance
Suggested Materials
Brass - Higher malleability than bronze or zinc.. By varying the
proportions of copper and zinc, the properties of the brass can be
changed, allowing hard and soft brasses.Aluminium makes brass
stronger and more corrosion resistant.Aluminium makes brass
stronger and more corrosion resistant.
Iron - Hard, wear-resistant, ductile, malleable, corrosion can be
prevented from powdered coating
Material of choice
Iron
Iron is suitable for the environment the wheelbarrow will be
used in because it has a high wear and tear resistance, its harder
than brass which make it last longer, it is not as ductile and
malleable compared to brass so it will maintain its function as a
bolt and also nut for an extended period of time.

Hinges Operating Environment
Promotes corrosion, sandy, high wear and tear
Suggested Materials
Stainless-steel - does not corrode, tough, high tensile strength,
ductile
Brass - Higher malleability than bronze or zinc.. By varying the
proportions of copper and zinc, the properties of the brass can be
changed, allowing hard and soft brasses.Aluminium makes brass

17

stronger and more corrosion resistant.Aluminium makes brass
stronger and more corrosion resistant.
Material of choice
Stainless- steel
J ustification of choice
Stainless-steel is perfect for the wet condition the wheelbarrow will
be used in. Furthermore, the high tensile strength possesed by
stainless-steel makes it an ideal candidate to be used compared to
brass which has a lower tensile strength.
Wheels Operating Environment
Sharp objects scattered on the ground, promotes corrosion
Suggested Materials
Plastic centered pneumatics wheel
Steel centered pneumatics wheel
Material of choice
Steel centered pneumatics wheel
Steel centered pneumatics wheel is harder than of plastic. Hence, the
steel centered pneumatics wheel suits perfectly for the operating
environment when compared to plastics centered pneumatics wheel.

3.4 CONFIGURATION DESIGN
3.4.1 PRODUCT ARCHITECTURE

Figure 6: Functional Structure

18

PART FUNCTIONAL ELEMENTS
BOLT Hold the tyre and bracket
BRACKET Hold tyre
NUT Lock and unlock with the bolt to hold tyre and bracket
WHEEL Move and reduce force during moving of the wheelbarrow
DOOR HINGE Act as axis of rotation which allow rotation between door and base
DOOR Open and close during loading and unloading process
FLOOR Acts as support for the load that being put
FLOOR
STAND
Support the floor
HANDLE Act as a grip to move the wheelbarrow
RECEPTACLE Support the structure of wheelbarrow from handle to tyre
STOPPER Acts as elevator to the floor which allows floor to rise and fall
LOCK Lock the door and stopper in place when loaded
Table 1: One-to-one mapping
The product architecture diagram above shows the function of each part and the
interaction between them.
As shown in the diagram, the connections between parts enable all parts to be
functional. For instance, the function of the handle shaft extended from the lock is to enable
control over machine during operation by counteracting the moments and forces produces
during moves the trolley. When shaft is turned 90 degrees, the extended lock rotates and
unlock the door and the stopper. The door and the stopper will then be free from static motion
during unloading process. Connection between stopper and floor allows the floor to incline
when the stopper inclines downwards from its static position. Now, as gravitational force
pulls the load to slide off the floor (downward), the load hit the door open to get off the
trolley.

3.4.2 PART CONFIGURATION

Figure 7: Product architecture-geometric layout

Rotation
- Reaction
force
removed
LOCK
Rotation
- Exerts
force on
floor
STOPPER
Rotation
- Allow
sliding
motion of
load
FLOOR
Rotation
by
momentum
of load
DOOR

19

Figure 8: Configuration requirement sketch
As shown as above, the basic concept is the floor of receptacle supported by a stopper.
The forces acting on floor when it is not unloading (floor horizontal) is sown at an end. The
rough scale dotted line shown represents the receptacle and the floor stand which supports the
floor. Then, we connect the stopper in various alternatives as noncontiguous part
configuration.

3.4.3 ANALYSING AND REFINING CONFIGURATION ALTERNATIVES
From here, the configuration alternatives are analyzed and refined.
A configuration check-list by categories:
Design for function
Design for assembly
Design for manufacture

3.4.3.1 DESIGN FOR FUNCTION
The wheel shaft should made by corrosion resistant metal such as stainless steel, for it is
strong enough to sustain the pressure and is resistant to corrosion, proving it long-lasting.
Stopper which supports the floor and the lock which block the stopper from inclining
during loaded period also receive very high reaction force at the joints. Internal force is also
high giving a chance to bend. Therefore, steel should be used here to prove maintainance and
reliability of the system.

20

User-friendliness can be achieved by having an ergonomic handle and rotatable
trolley wheels. These allow users to steer the trolley with ease.
Mechanism-wise, our product has to be easy to use. With just a simple rotation of the
shaft extended from the lock, a full unloading mechanism will be able to perform. To restore
the system, the user only has to step on the pedal extended from the stopper and then return
the lock into vertical position. According to the estimated calculations, accompanied by a few
assumptions, energy needed to activate unloading system is low compared to lifting the
whole cart.
Having only the floor inclined, users actually have their body parts protected from
being clamped in between components when restoring the system (i.e.: unlike dump cart
system which tilts the whole receptacle when unloaded.
The four-wheeled system solves the balancing problem which is commonly found
when using wheelbarrows. This again proves safety, user-friendliness, and stability.

3.4.3.2 DESIGN FOR ASSEMBLY (DFA)
By merging parts, for example, directly extending pedal from stopper and extending a handle
shaft from lock, these minimize part counts. Standard parts, bolts and nuts; hinges; and
wheels, are used. Self-locating features are found throughout the receptacle to fix floor, floor
stand, stopper, and lock in place.

3.4.3.3 DESIGN FOR MANUFACTURE
DONT

DO

Minimize variation of standard part sizes.

DONT

DO

Minimize part count by incorporating multiple functions into single parts.


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3.4.4 REFINING ALTERNATIVE CONFIGURATION
Use hollow tube instead of rod to reduce weight.
Avoid changes in thickness when possible.
Avoid sharp corners as they produce stress concentration. Fillet corners.
Do not use narrow web. Narrow web causes bulging which will eventually tear.

3.4.5 EVALUATING ALTERNATIVES
For each criteria, marks is given whether the concept is better (+), worse (-) or more or less
the same (S) as the datum. Each of other unit of knowledge is similarly rated, by using
similar marking system. On the other hand, Weighted Rating Method is used which is
similarly to matrix layout as the modified Pughs method.
PUGHS MODIFIED CONCEPT SELECTION METHOD

3.5 PARAMETRIC DESIGN
3.5.1 DESIGN VARIABLE VALUES
The main aim of the design is to unload the trolley without any lifting action. To achieve this,
the angle of inclination without lifting action.
LEVER
Criteria Importance
Wt. (%)
Concept Alternatives
Bent at
single edge
lever
Straight Lever Curved Lever
Production
Cost
20 D + -
Effectiveness 30 A + +
Reliability 30 T + +
Life Span 20 U + -
100 M
+ 0 100 60
- 0 0 40
S 100 0 0

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To find the angle of inclination:

Target for theta:

b = position of floor before inclined diameter
of stopper
= 10.8 2
= 8.8 cm

Simply setting the position of the pivot,
Let c = 49.5 cm

When the floor drops, c is repositioned as
hypotenuse.

Now, = sin
-1

= sin
-1

= 10.24
o
> 10
o
; Therefore, target angle
achieved.
3.5.2 MANUFACTURING PROCESSES
Special Parts Manufacturing Process
Receptacle Injection Moulding
Floor Injection Moulding
Floor Stand Injection Moulding
Door Injection Moulding
Handle Wood Bending
Lock Rolling and Welding
Stopper Rolling and Welding
Table 2 Manufacturing processes chosen for each part
3.5.3 PERFORMANCE PREDICTION
To find the angle of inclination:

Now, weve set
Diameter of slot = 2 cm
e = 1.5 cm
= 21
o

a = e sin
a = 1.5 sin 21
o
a = 0.5376

b = 8.8 cm
c = 49.5 cm

When the floor drops, c is repositioned as
hypotenuse.

Now, = sin
-1

= sin
-1

= 11
o


23

3.5.4 DIMENSIONS
To minimize possibility of fracture at parts, a safety factor of 2 is recommended.
At weakest joint B on Floor, r x t > 2.10 E -5
Safety factor = (0.008 x 0.008) /(2.10 E -5) = 3 > 2
4.0 SELECTED DESIGN
4.1 OVERVIEW
With all the above results, Load Propelling Trolley is proven to be better in industrial areas
because:
The floor remaining horizontal when loaded allows loads of rectangular shapes (i.e.
bricks).
Lever system used can reduce force needed to incline the floor of receptacle when
unloading is pulled by gravitational force.
Only the floor is inclined and not the whole receptacle, reducing the chances of
clamping hazard. Safety feature is increased.
Four-wheeled is proved to be more stable and easier to be handled.
Hind wheels are rotatable which allows steering. Trolley can be directed with ease.
Ergonomic continuous handle provides comfort and working capability of user.
Material used has high tensile strength, namely HDPE and steel.
Parts are either coated with corrosion resistant materials or manufactured from no
corrosion materials.
Modular system of the trolley keeps maintenance convenient.

4.2 DETAIL DESIGN
The following is the assembly view of the final product:

24

4.3 PRODUCT SPECIFICATIONS
Functional Depth 32 cm
Functional Width 58 cm
Functional Length (Upper) 98 cm
Functional Length (Lower) 85 cm
Water Capacity 170 L
Maximum Load Capacity 500 kg
Product Height 78 cm
Product Width 61 cm
Product Length 105 cm
Angle of Floor Inclination (before unloading) 0
o

Angle of Floor Inclination (after unloading) 11
o
Approximate estimated Force needed to restore system 0.06 N
Table 3: Load Propelling Trolley Specification

4.4 DETAIL DESIGN CONSIDERATIONS
Economic
Materials chosen for our product are affordable and durable. For example, we avoid
choosing aluminium because it is too expensive. Instead, we chose the low cost steel
which also has very high tensile strength. Our product has high marketing potential
especially when its result is proven to increase production at industrial sites,
Environmental

25

Long lasting HDPE can be well maintained for a long period of time. Product can be
reused for multiple industrial project with care and not renew the trolley. When the
trolley is no longer in use, HDPE can be recycled into other products. Steel is found
redundant on Earth. Steel can be extremely reliable and has long life, and on the plus
point, steel is environmental friendly to Earth.
Health and Safety
Handle manufactured from bright oak. It is skin-friendly, no allergy causes, and has
allowable friction between the handle and users hand. Only the floor is inclined, which is
out of users reach. Clamping hazard is reduced. No lifting action is required. This saves
muscle aches from supporting the weight of load during unloading.
Manufacturability
Parts can be manufactured using current technology. Mass production can be obtained
within short period of time with precision and accuracy.
5.0 CONCLUSION
After months of hard work and sacrifices, we have finally produced our final design
product Load Propelling Trolley. We have applied the knowledge we learned from lecture
in our project design process. It is impossible to reach this point without proper coordination,
ethics, and teamwork among our team members. From this project, we had acquired skills as
mentioned above required for a good engineer.
We have learned that proper procedures are needed in any design project. We also
learned that decision making is very important. In order to make the most optimal decision,
we needed to input the correct information. We have done lots of research by browsing the
internet, searching for information from the books in the library as well as obtaining advice
from other group and also experienced seniors. We have organized group meetings several
times to discuss about our ideas and opinions, and finally make the best decision of all.
We have encountered a lot of hardships throughout our design project. Through our
teamwork and sacrifices from our team members, we have finally to overcome those
obstacles and problems coming in our way. Through this design project we have strengthened
our mastery on the conceptual design theories and knowledge such as formulation of
problems, design concept, configuration design as well as parametric design.

The skills and knowledge acquired from this design project will surely benefits us a
lot in our future career as an engineer.

6.0 REFERENCE
Trolley Wheel
http://www.electrictrolleyspares.com/powakaddy_legend_p4.htm#

26

Wheelbarrow
http://www.letstalkscience.ca/hands-on-activities/engineering-technology/how-does-a-
wheelbarrow-help-you-to-carry-heavy-loads.html
Patent Search
http://www.google.com/patents/US6193319
History of wheelbarrows
http://www.uh.edu/engines/epi377.htm
Wheelbarrows Specifications
http://www.alibaba.com/product-detail/wheelbarrows-WB6209-wheelbarrow-specifications-
standard_988143096.html?s=p
http://www.homedepot.com/p/Jackson-6-cu-ft-Steel-Wheelbarrow-M6KBUT11/100325962
http://www.homedepot.com/p/True-Temper-6-cu-ft-Poly-Wheelbarrow-with-Dual-Wheels-
CP6DWUT8/202616068?N=5yc1vZc5qk
http://www.homedepot.com/p/Unbranded-4-cu-ft-Gorilla-Carts-Plastic-Garden-Dump-Cart-
GOR200B/202353037?N=5yc1vZbx50
Customers Requirement
http://www.wikihow.com/Buy-a-Wheelbarrow
Product Architecture
http://citeseerx.ist.psu.edu/viewdoc/download?doi=10.1.1.183.3175&rep=rep1&type=pdf

Friction Coefficient
http://www.tribology-abc.com/abc/cof.htm
http://www.finesoftware.eu/help/geo5/en/table-of-ultimate-friction-factors-for-dissimilar-
materials-01/
Wood Manufacturing Process
http://www.tai-workshop.com/english/tech-2(b)-e.html
Wood Specification
http://www.matbase.com/material-categories/composites/polymer-matrix-composites-
pmc/wood/class-4-wood-slightly-durable/material-properties-of-red-oak-
wood.html#properties
Steel Specification
http://www.azom.com/article.aspx?ArticleID=6130
Polyethylene Specification
http://www.sdplastics.com/polyeth.html

27

Text
Engineering Design, Rudolph J. Eggert, Boise State University, Pearson, Prentice Hall, ISBN
9780131433588

7.0 APPENDIX

ALTERNATIVE INCLINATION
SYSTEM OF
RECEPTACLE
HANDLE
TYPE
RECEPTACLE
FLOOR
ORIENTATION
WHEEL
TYPE
UNLOADING
PATH
1 Lever Continuous Horizontal
Tray
Trolley
Wheels
With door
Tray
Trolley
Wheels
No door
Tray
Threaded
wheels
With door
Tray
Threaded
wheels
No door
5 Lever Continuous Slanted tray Trolley
Wheels
With door
6 Lever Continuous Slanted tray Trolley
Wheels
No door
7 Lever Continuous Slanted tray Threaded
Wheels
With door
8 Lever Continuous Slanted tray Threaded
Wheels
No door
9 Lever T-shaped Horizontal
Tray
Trolley
Wheels
With door
Tray
Trolley
Wheels
No door
Tray
Threaded
wheels
With door
Tray
Threaded
wheels
No door
13 Lever T-shaped Slanted tray Trolley
Wheels
With door
Wheels
No door
15 Lever T-shaped Slanted tray Threaded
Wheels
With door
Wheels
No door
17 Lever Projected
two arms
Horizontal
Tray
Trolley
Wheels
With door

28

18 Lever Projected
two arms
Horizontal
Tray
Trolley
Wheels
No door
19 Lever Projected
two arms
Horizontal
Tray
Threaded
wheels
With door
20 Lever Projected
two arms
Horizontal
Tray
Threaded
wheels
No door
21 Lever Projected
two arms
Slanted tray Trolley
Wheels
With door
22 Lever Projected
two arms
Wheels
No door
23 Lever Projected
two arms
Slanted tray Threaded
Wheels
With door
24 Lever Projected
two arms
Wheels
No door
25 Hydraulic
cylinder
Continuous Horizontal
Tray
Trolley
Wheels
With door
26 Hydraulic
cylinder
Tray
Trolley
Wheels
No door
27 Hydraulic
cylinder
Tray
Threaded
wheels
With door
28 Hydraulic
cylinder
Tray
Threaded
wheels
No door
29 Hydraulic
cylinder
Continuous Slanted tray Trolley
Wheels
With door
30 Hydraulic
cylinder
Continuous Slanted tray Trolley
Wheels
No door
31 Hydraulic
cylinder
Continuous Slanted tray Threaded
Wheels
With door
32 Hydraulic
cylinder
Continuous Slanted tray Threaded
Wheels
No door
33 Hydraulic
cylinder
T-shaped Horizontal
Tray
Trolley
Wheels
With door
34 Hydraulic
cylinder
T-shaped Horizontal
Tray
Trolley
Wheels
No door
35 Hydraulic
cylinder
T-shaped Horizontal
Tray
Threaded
wheels
With door
36 Hydraulic
cylinder
T-shaped Horizontal
Tray
Threaded
wheels
No door
37 Hydraulic
cylinder
T-shaped Slanted tray Trolley
Wheels
With door
38 Hydraulic
cylinder
T-shaped Slanted tray Trolley
Wheels
No door
39 Hydraulic
cylinder
T-shaped Slanted tray Threaded
Wheels
With door
40 Hydraulic
cylinder
T-shaped Slanted tray Threaded
Wheels
No door
41 Hydraulic
cylinder
Projected
two arms
Horizontal
Tray
Trolley
Wheels
With door

29

42 Hydraulic
cylinder
Projected
two arms
Horizontal
Tray
Trolley
Wheels
No door
43 Hydraulic
cylinder
Projected
two arms
Horizontal
Tray
Threaded
wheels
With door
44 Hydraulic
cylinder
Projected
two arms
Horizontal
Tray
Threaded
wheels
No door
45 Hydraulic
cylinder
Projected
two arms
Wheels
With door
46 Hydraulic
cylinder
Projected
two arms
Wheels
No door
47 Hydraulic
cylinder
Projected
two arms
Wheels
With door
48 Hydraulic
cylinder
Projected
two arms
Wheels
No door
49 Pulley Continuous Horizontal
Tray
Trolley
Wheels
With door
Tray
Trolley
Wheels
No door
Tray
Threaded
wheels
With door
Tray
Threaded
wheels
No door
53 Pulley Continuous Slanted tray Trolley
Wheels
With door
54 Pulley Continuous Slanted tray Trolley
Wheels
No door
55 Pulley Continuous Slanted tray Threaded
Wheels
With door
56 Pulley Continuous Slanted tray Threaded
Wheels
No door
57 Pulley T-shaped Horizontal
Tray
Trolley
Wheels
With door
Tray
Trolley
Wheels
No door
Tray
Threaded
wheels
With door
Tray
Threaded
wheels
No door
Wheels
With door
Wheels
No door
Wheels
With door
64 Pulley T-shaped Slanted tray Threaded
Wheels
No door
65 Pulley Projected
two arms
Horizontal
Tray
Trolley
Wheels
With door

30

66 Pulley Projected
two arms
Horizontal
Tray
Trolley
Wheels
No door
67 Pulley Projected
two arms
Horizontal
Tray
Threaded
wheels
With door
68 Pulley Projected
two arms
Horizontal
Tray
Threaded
wheels
No door
69 Pulley Projected
two arms
Wheels
With door
70 Pulley Projected
two arms
Wheels
No door
71 Pulley Projected
two arms
Wheels
With door
72 Pulley Projected
two arms
Wheels
No door

Coefficient of friction for a range of material combinations
combination Static Dynamic
dry lubricated dry lubricated
steel-steel 0.5...0.6 0.15 0.4...0.6 0.15
copper-steel - - 0.5...0.8 0.15
steel-cast iron 0.2 0.1 0.2 0.05
cast iron - cast iron 0.25 0.15 0.2 0.15
friction material - steel - - 0.5-0.6 -
steel-ice 0.03 - 0.015 -
steel-wood 0.5-0.6 0.1 0.2-0.5 0.05
wood-wood 0.4-0.6 0.15...0.2 0.2...0.4 0.15
leather-metal 0.6 0.2 0.2...0.25 0.12
rubber-metal 1 - 0.5
plastic-metal 0.25...0.4 - 0.1...0.3 0.04...0.1
plastic-plastic 0.3-0.4 - 0.2...0.4 0.04...0.1

CALCULATION
To find force required to unload MAXIMUM LOAD CAPACITY: LOAD = 500 kg


31

Using figure (c),
, Hx = Dx
, Dy = 0.93 (9.81) = 9.1233 = 9.12 N
, -(0.10 cos 20
o
)(9.1233) (0.20 cos 20
o
)Dx + (0.20 sin 20
o
)(9.1233) = 0
Dx = -1.095867 = -1.10 N

Using figure (b),
, Dx = - Bx
Bx = 1.095867
, 0.43445(506.534)(9.81) 0.495 Cy + 0.8689 Dy = 0
Cy = 2166.75210 = 2167 N
, By + Cy Dy 506.534(9.81) = 0
By = 2811.46974 = 2811 N

Using figure (a),
, -(0.0405 cos 5.6
o
)(0.968)(9.81) + (0.1225)Q + (0.3925 cos 5.6
o
+
0.05)(0.174)(9.81) (0.4735 cos 5.6
o
)By + (0.4735 sin 5.6
o
) Bx = 0
Q = 1324.55373 = 1325 N
Users only have to overcome Q and static friction between lock and stopper to unload.

For single-wheeled wheelbarrow, force needed for lifting action, Z, lets say, not considering
its capability, 500 kg is:
Distance between rotation axis and load center of gravity = 0.46 m
Distance between rotation axis and point of exertion of force = 1.22 m
Z = 0.46 x 500(9.81) / 1.22
Z = 1849 N
Therefore, our target for designed product is to unload the trolley with force > 1849 N.

To find force required to restore system:
LOAD = 0 kg

Remove Q. Add in P at the end of pedal.

32

Using figure (c),
, Hx = Dx
, Dy = 0.93 (9.81) = 9.1233 = 9.12 N
, -(0.10 cos 20
o
)(9.1233) (0.20 cos 20
o
)Dx + (0.20 sin 20
o
)(9.1233) = 0
Dx = -1.095867 = -1.10 N

Using figure (b),
, Dx = - Bx
Bx = 1.095867
, 0.43445(6.534)(9.81) 0.495 Cy + 0.8689 Dy = 0
Cy = 72.27262 = 72.3 N
, By + Cy Dy 6.534(9.81) = 0
By = 0.94942 = 0.95 N

Using figure (a),
, -(0.0405 cos 5.6
o
)(0.968)(9.81) + (0.3925 cos 5.6
o
+ 0.1) P + (0.3925 cos 5.6
o
+
0.05)(0.174)(9.81) (0.4735 cos 5.6
o
)By + (0.4735 sin 5.6
o
) Bx = 0
P = 0.05585 = 0.06 N
All joints : A, B, C, D, Q
When loaded with MAXIMUM LOAD:
Stopper
Bx = 1.10 N
By = 2811 N
Q = 1325 N

Calculate Ax and Ay.
Using figure (a),
, Ay P 0.174(9.81)
0.968(9.81) By = 0
Ay = 17.2145 = 17.2 N
, - Ax Bx = 0
Ax = -1.09587 = - 1.10 N

Floor
Bx = 1.10 N
By = 2811 N
Cy = 2167 N
Dx = -1.10 N
Dy = 9.12 N

Highest shear force detected: Axial B


33

For Floor, material chosen is HDPE.
Shear stress < 21.3 MPa
Shear stress = F/ (2r x t)
21.3M > By / (2r x t)
21.3 M> 2811 / (2r x t)
r x t > 2.10 E -5 m

At Axial B, material chosen is steel.
Shear stress < 570 MPa
Shear stress = F/ (r
2
)
570 M > By / (r
2
)
570 M > 2811 / (r
2
)
r > 1.57 E -6 m
There are certain joints which experience high tensile strength and may face fracture if the
cross-sectional area of these portions is not taken care.

To minimize possibility of fracture at parts, a safety factor of 2 is recommended.
At weakest joint B on Floor, r x t > 2.10 E -5
Safety factor = (0.008 x 0.008) /(2.10 E -5) = 3


34

2D DRAWING


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Load Propelling Trolley Design Report

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