Swinburne University of

Technology Sarawak
Design Project
Motorized Wheel Barrow
MEE40002 Mechanical System Design

Group members:
Philip Chin Kai Wen 7434243
Kuek Pheck Ching 7434650
Don Kushan 4311019
Lim Yong Sheng 7440790
Contents
Table of Figures.....................................................................................................................................4
List of Tables.........................................................................................................................................5
1. Introduction...................................................................................................................................1
2. Literature Review..........................................................................................................................3
2.1 Design theory...............................................................................................................................3
2.2 Wheels and stability.....................................................................................................................5
2.3 Sprocket.......................................................................................................................................6
2.3.1 Multiple strand sprockets......................................................................................................6
2.4 Chain and Sprocket Selection......................................................................................................7
2.4.1 Selection of roller chain drives.............................................................................................8
2.4.2 Engineering Data and Design...............................................................................................9
3. Concept Generation and Concept Selection.................................................................................30
3.1 Concept Generation...................................................................................................................30
3.1.1 Morphological Chart and the Selection Outcome...............................................................31
3.1.2 Weighted Objectives...........................................................................................................33
3.2 Concept Selection......................................................................................................................35
4. The Design of Motorised Wheel Barrow.....................................................................................37
4.1 Motor Selection.........................................................................................................................37
4.2 Transmission system..................................................................................................................42
4.2.1 Sprockets............................................................................................................................42
4.2.2 Chain..................................................................................................................................43
4.3 Batteries.....................................................................................................................................44
4.4 Wheel.........................................................................................................................................45
4.4 Prototype of the motorized wheel barrow..................................................................................47
4.4.1 Wheel and Sprocket configuration......................................................................................47
4.4.2 Motor..................................................................................................................................49
4.4.3 Chain..................................................................................................................................50
4.4.4 Battery................................................................................................................................51
4.4.5 Electronic Speed Controller................................................................................................52
5. Documentation.............................................................................................................................53
5.1 Solidworks Drawings.................................................................................................................53
5.2 Electronic circuit Diagram of the Motorised Wheel Barrow......................................................57
6. Conclusion...................................................................................................................................58
7. Recommendations.......................................................................................................................58
8. References...................................................................................................................................59
9. Appendix.....................................................................................................................................60
Appendix 1 Gantt chart.................................................................................................................60
Appendix 2 Meeting minutes........................................................................................................62
Meeting minutes 1.......................................................................................................................62
Meeting minutes 2.......................................................................................................................63
Meeting minutes 3.......................................................................................................................64
Meeting minutes 4.......................................................................................................................65
Meeting minutes 5.......................................................................................................................66
Meeting minutes 6.......................................................................................................................67
Meeting minutes 7.......................................................................................................................68
Meeting minutes 8.......................................................................................................................69
Meeting minutes 9.......................................................................................................................70
Meeting minutes 10.....................................................................................................................71
Meeting minutes 11.....................................................................................................................72
Appendix 3 Safe Design...............................................................................................................73
Table of Figures
Figure 1: Different types of engineering designing process...................................................................3
Figure 2: Different types of tires considered..........................................................................................5
Figure 3: Different types of sprocket hub..............................................................................................6
Figure 4: Strands of the sprockets..........................................................................................................6
Figure 5: QD and MST sprockets..........................................................................................................7
Figure 6: Chain length...........................................................................................................................7
Figure 7: Horizontal and Vertical Conveyors.......................................................................................10
Figure 8: Inclined Conveyors...............................................................................................................11
Figure 9 Centre Distance of Chain Drive.............................................................................................12
Figure 10: S-N curve of a chain...........................................................................................................13
Figure 11: Wear Characteristics...........................................................................................................14
Figure 12: Bush Assembly...................................................................................................................14
Figure 13: Different types of chains....................................................................................................15
Figure 14: Compound Gear Train........................................................................................................17
Figure 15: 18T one way sprocket.........................................................................................................18
Figure 16: 9T Sprocket........................................................................................................................18
Figure 17: Fuel Operated Motor..........................................................................................................19
Figure 18: Selected motor....................................................................................................................20
Figure 19: Dimensions of the MYZ1016Z2 motor..............................................................................21
Figure 20: Performance graph of motor...............................................................................................21
Figure 21: Lead Acid Battery...............................................................................................................22
Figure 22: Lithium battery...................................................................................................................23
Figure 23: Descriptive Model..............................................................................................................24
Figure 24: Prescriptive Model.............................................................................................................25
Figure 25: Example of morphological chart for a vegetable collection method...................................26
Figure 26: Example for weighted objectives........................................................................................27
Figure 27: Rim Support.......................................................................................................................27
Figure 28: Sprocket-rim assembly.......................................................................................................28
Figure 29: Motor mounted under the bucket of wheel barrow.............................................................28
Figure 30: Batteries bracket.................................................................................................................29
Figure 31: The wheel barrow in 2D.....................................................................................................37
Figure 32: MY1016Z2 DC Motor........................................................................................................41
Figure 33: Motorised wheel barrow transmission................................................................................42
Figure 34: Chain system......................................................................................................................43
Figure 35: Selected battery..................................................................................................................44
Figure 36: Wheel of the wheel barrow.................................................................................................45
Figure 37: One Way Sprocket..............................................................................................................47
Figure 38: metal part to be welded with sprocket and be bolted to the rim..........................................48
Figure 39: One way sprocket welded to the rim..................................................................................48
Figure 40: Motor configuration...........................................................................................................49
Figure 41: ANSI #40 Chain.................................................................................................................50
Figure 42: Chain drive.........................................................................................................................50
Figure 43: Batteries at the back of wheel barrow.................................................................................51
Figure 44: Electronic Speed Controller and Throttle Grip...................................................................52
Figure 45: Top view of Wheel Barrow.................................................................................................53
Figure 46: Front View of Wheel barrow..............................................................................................54
Figure 47: Side View of Wheel Barrow...............................................................................................54
Figure 48: Isometric View of Wheel Barrow.......................................................................................55
Figure 49: Configuration of motor, sprockets and chain......................................................................56
Figure 50: Battery Placement and Throttle Grip..................................................................................56
Figure 51: Configuration for the electronics........................................................................................57
Figure 52: Circuit Diagram..................................................................................................................57

List of Tables
Table 1: The approximate Wt./Ft of standard roller chain......................................................................9
Table 2: Specification of Gasoline Motor...........................................................................................19
Table 3: Performance values of the Motor...........................................................................................22
Table 4: Specification of Motor...........................................................................................................22
Table 5: Model Selection 1 (Word in red is the selected option)..........................................................31
Table 6: Model Selection 2 (Word in red is the selected option)..........................................................31
Table 7: Selection Outcome.................................................................................................................32
Table 8: Table of Criteria and its Description......................................................................................33
Table 9: Table of Weighted Objective..................................................................................................34
Table 10: Specification of the chosen motor........................................................................................41
Table 11: Gantt Chart...........................................................................................................................60
Table 12: Task Description..................................................................................................................61
Table 13: FMEA analysis.....................................................................................................................73
1. Introduction
A wheelbarrow is basically defined as an effective tool which helps people transport
heavy loads to a certain desired location. However, one disadvantage of using a
wheelbarrow to a user is that it doesnt have an automation system. The motorized
wheelbarrow aims to add an automation system which will help people with ease when
carrying a heavy load.

By research there a lot of wheelbarrows present such as the, life time wheelbarrow,
Jackson wheelbarrow, and the gorilla cart, but these wheelbarrows still did not have the
motorized or automated performance. However, a product name power buggy did have a
motor installed but it cost more than the usual wheel barrow. Therefore it so more targeted
for business use but no the everyday handyman works.

The team has been assembled and are required to design a motorized wheelbarrow. The
requirement of the wheelbarrow project is to lift a 20kg load on a 15 degrees inclination
plane. The power to the motor is only what has been provided by our lecturer, which is a
12v lead acid battery.

The design project will show all the theories used to design the motorized wheelbarrow. It
would also show what kind of alternatives were used when selecting the proper
equipment for the wheelbarrow, most importantly the rated decision on what the team
selected by calculations. Experience and knowledge gained from our engineering subjects
will enable the team to characteristics the model wheelbarrow depicts, i.e. the stability of
the wheels, assembly and the power systems of the product.

The mechanical system design project is indeed a good way for the team to gain more
designing strategies and develop our skills as a mechanical engineer. The team will use a
lot of research techniques and many information gathering methods to get the absolute
version of the motorized wheelbarrow fully functional and to make a successful project.

The design phase of the wheelbarrow was initiated by carrying out options in order to
find the optimum motor to drive the wheelbarrow. Further through research and
calculations we decided that the motor MY1016Z2- 250W- 24 v would be the optimum
motor for the drive motor. A sprocket attached to the wheel and a simple chain drive was
installed from the motor to the sprocket.

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Once the components were completed and the important equipment acquired, assembly of
the wheelbarrow took place. The final motorized wheelbarrow assembly was achieved by
using, TIG welding, nut and bolt, and metal cutting band saw. Lathe machine used to
obtain the wheel rim to have attached the sprocket. All the components were painted in
order to prevent them from rusting

Through numerous testing, the motorized wheelbarrow successfully proved to meet the
requirements. The motorized wheelbarrow successfully carried a 20 kg load across a 15
degrees incline. Additionally the wheelbarrow could lift more than the intended load
requirement, even the incline plane in degrees was increased it could still lift without any
trouble.

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 2. Literature Review

2.1 Design theory

The design process for engineering consists of different various steps when it comes to
designing or creating various tools or products to satisfy customer preference. In many cases,
technology which are designed in order to satisfy needs for customers whereas when it comes
to engineering it resorts to the process where new technology is already been created.

Figure 1: Different types of engineering designing

process

The figure above shows the engineering design process taken during designing a product. The
diagram does not show any arrow heads that means in reality it can go either anti clockwise
or clockwise to the required adjacent stage.

The first step in designing a product is to ask, means that the designer should identify the
need and constraints. To identify the need a lot of research should be done. The purpose of
designing is to build something new which will innovate other engineers and other people
who have similar interest.

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The second is to research the problem, where an immense amount of researching done in this
stage in order to retrieve information that will help the designer to help themselves in
building the product.

The third stage is to imagine. Here the designer will be developing possible solutions and
eliminating problems. It is indeed a good practice to imagine the products mechanism, which
will help us to picture the movements and then add more details to your imagination to figure
out details such as materials and components to be added. Since you visualize certain parts
you will be able to add or remove parts independently during visualization.

The fourth stage is to plan and have to select a promising solution. This stage we convert our
imagination to visual format on paper. This plan should highly consists of simulations, maps,
and diagram etc. this stage you will be able to come across flaws in your imagination product
and thus to correct it, you can back to the previous stage and can come back to modify in the
planning stage and then further manipulate your plans to achieve the optimum product
solution. Most of the designers who follow this engineering process tend to build a prototype
but we did not use that method.

The fifth stage of the engineering design process is to create. This is where the actual
prototype is built. The perseverance of a prototype is to test the product for errors and
performance, however the prototype is not considered as the final product because it could
have flaws and not put to the real world. By building the prototype not all the creation we
intended to do is done here, as this will be done in the final product.

The next stage after the creation stage is the testing and evaluating stage of the prototype.
This is where the prototype is tested which was built in the previous stage. However, there
are two types of testing. One is the white box testing and the other is the black box testing.
White box testing is testing for internal independent functions step by step, whereas black
box testing is the output should coincide with input. During this stage a lot of errors are
bound to be found, if no errors are found that means the testing is not done properly and the
prototype is at a bad stage. This stage has least cost involved but the time consumption is way
more.

The seventh stage is to improve and redesign as needed. The errors encountered during the
previous stage are modified here for optimum performance. The product is improved here
and known as the maintenance stage. All the errors are eliminated and the final product has

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been made. In order to improve the engineering design process we can go to the next stage
which is to ask, which the first stage of the design process is. This shows that the engineering
design process is a cycle and can move forth and back between certain stages to improve your
final product.

2.2 Wheels and stability

This section we see how the stability of the wheels work. By having one wheel at the front of
the wheel barrow will be versatile in maneuvering small loads. There is a better control when
the load is removed from the wheelbarrow. Having two wheels will make the wheelbarrow
more stable on the ground level and it is not completely versatile.

There are two types of tires considered. One is the solid rubber tire and the other is pneumatic
tire.

Figure 2: Different types of tires considered

The solid rubber tire will not go flat as its not air inflated. It is rather heavy so will withstand
punctures and debris, this will make easy for the consumers as the tire need not be changed. It
is also maintenance free. The thread is ribbed and the hub length of the tire is normally 3
centered Hub. The bearing size roller bearing. The rubber tire is 12 x 3 solid crumb
rubber tire which is made up of recycled rubber tires. The tire diameter is approximately 13
inch and the maximum load it can carry is 500 lb.

The pneumatic tire is air inflated. There is a better shock absorption and is much lighter than
solid rubber tire. There is however a risk failure due to punctures and debris. The tire size is
approximately 6 x 1.50. Tire diameter is 6 and the load capacity is 40 lbs. The weight of the
tire is 1.5lbs.

2.3 Sprocket
In the American manufacturing of sprockets they have come across with 4 specific types of sprockets.
They are the single type A Hub, B hub, C hub and D hub.

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2.3.1 Multiple
strand sprockets
It is normally
listed by the
prefix known as E for triple strand or D for double strand and f for quadruple. There
are more sprockets in various other styles in addition to the four specific types.

Figure 3: Different types of sprocket hub

Figure 4: Strands of the sprockets

There are various types of sprockets. Sprockets such as QD (Quick detachable) sprockets is a
type of sprockets where the bushing of the sprocket it bolted into the bore of the sprocket. A
tight grip is provided when the bushing is compressed onto the shaft. Another bushed
sprocket named as MST (Martin split taper) is much similar to the quick detachable sprocket
where the bushing is similar and the style too, the only difference is that it contains an
external key that fit directly to the driven product. The TB (taper bushed) sprocket is an
interchangeable sprocket which in turn provides a positive grip on the drive shaft.

Figure 5: QD and MST sprockets

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2.4 Chain and Sprocket Selection
There are certain procedure to take into account when selecting a chain and a sprocket:

First you need to determine the class of driven load.

Secondly the service factor should be known
Thirdly the horsepower for the design should be calculated
Select chain pitch
Select number of teeth in the given small sprocket.
Determine the number of teeth in the given large sprocket
Determine the center distance
Calculate chain length

Figure 6: Chain Length

2.4.1 Selection of roller chain drives

To design a prefect roller chain drive to achieve maximum efficiency the procedure below are
listed.

1 Compute the input horsepower e.g.: electric motor

2 What kind of equipment to be driven
3 What horsepower to be transmitted
4 Compute the full load speed in RPM of the fastest running shaft

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 5 Compute the total desired speed of the slow speed in RPM of the shaft
6 Diameters of the driving and driven shafts
7 Measure or calculate the center to center distance to the shaft
8 Acknowledge the position of space and drive limitations
9 What kind of lubrication method to be used
10 What are the possible conditions of drive, hours or operation, lubrication, and
fluctuating and steady load?

2.4.2 Engineering Data and Design

The Horsepower can be calculated in the following equations mentioned below. The
horsepower is equal to 33,000 foot lb/m. to calculate speed and chain load the following
equations are considered. T is known as the sprocket teeth and P is known as the chain pitch.

The chain working load can be calculated by using the known horsepower input and working load of
the desired chain,

The chain speed can be calculated from the following formula where T is known as the sprocket teeth
number and the K is known as the pitches of chain per foot

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 Table 1: The approximate Wt./Ft of standard roller chain

The factor of
safety can be determined by the following equation which is shown below.

The shaft torque is normally greater for the driven shaft than that of the driving shaft due to
the varying RPM and sprocket sizes the shaft torque is determined by the following equation.

Conveyor chains

The design used in chains which implies to conveyers should be specifically selected from
the theory of the chain pull and the maximum working load of the drive chain. Large pitch
chains are used so they provide attachment spacing; this is an advantage as it would increase
the life of the conveyer.

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Figure 6: Horizontal and Vertical Conveyors

H (ft) = the total horizontal projection of the length of the conveyor

V (ft) = the vertical projections of the length of the conveyor
W (pounds) = material handled weight per foot of conveyor length
P (pounds) = weight /f of all moving conveyor parts (two or single strand)
F = the friction coefficient of chain on runway
Chain Pulls

The pull or the force required to move the conveyor contains the pull essential to move the
weight of chain and material. The formula shows how to determine the total chain pull. If the
chain conveyor is double or single, the formula applies the same. If the strand conveyor is
parallel the pull per chain is known to be one half of the figure which is calculated from the
given formula.

Figure 7: Inclined Conveyors

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The formula for the pull of chains is = f H (W+ P) + V (W+ P)

Chain Length Calculation

The following formula for chain length can be calculated for any two sprocket drive.

C = Distance of the shaft from the center and measured in pitches,

L = Length of chain in pitches,

N = No. of teeth in larger sprocket,

n = No. of teeth in smaller sprocket,

= 3.1416,

A = This is calculated from the catalogue data for ( N-n),

P = Pitch of chain.

Figure 8 Centre Distance of Chain Drive

Chain performance

The performance of a chain can be computed by the Reynolds chain products, where they are
dimensionally in line with the specified ISO standard, and also they satisfy the ISO minimum
tensile strength requirement. By considering the Reynolds chain product there is a factor they
do not consider, that is that it ignores the principal of fatigue and wear factors. By
independent testing Reynolds chains prove that by designing they produce the best results. In

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the Reynolds catalogue the ISO breaking load is quoted and the test results tested
independently shows that they achieve the breaking load which were far excess of the ISO
minimum.

The performance of a chain is computed by a various factors. The tensile strength is one
important factor, where the chain installation is roughly known. The Reynolds products
constructed by steel have yield strength of 64 % of the ultimate yield strength. Any load
applied above this yield strength limit will cause rapid failure and deformation.

Figure 9: S-N curve of a chain

Reference to an S-N curve at 64 % will conclude that at loads below 64 % will have a finite
life and the reductions in load may expect increase in life until and when the fatigue
endurance limit is reached, at approximately 8000000 operations. Loads below 10000000
will result in an infinite fatigue life. When these numbers of operations are conducted the
failure mode will become wear related, which is indeed considered as a safer procedure.

Reference to the wear characteristics graph shows that the chain wears in three different
wears. The first phase is known as the bedding in where the change in chain length is a very
rapid change where the components adjusting from the load which are enforced on them.
The second phase is known as the initial wear, this is the phase where the mating spots of
the bush and pin imposes rapid abrasion of the local high spots. The assembly diagram shown
below states clearly that where the good fatigue life is, and where the plate and the bush is
and also where the high degree of interference fit is at.

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Figure 10: Wear Characteristics

Figure 11: Bush Assembly

Wear factors

As already discussed above for the wear factors we can conclude that wear occurs when the
friction between the bush and the pin occurs. The rate of wear is determined by the specific
pressure and the bearing area. The bush and the pin are eroded such a way that the chains are
elongated. In this case the elongation will be a maximum of 2% of that of the nominal chain.
However the elongation of a chain should be limited to 1 % when these conditions are
satisfied.

Teeth of a sprocket should contain 90 teeth or more.

Synchronizations should be done perfectly. The center distance should be greater than
the recommended values.

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Wear depends on these conditions in a drive system

Speed- For accelerating wear, when the speed of the system is high, the frequency of
the bearing is high as well for bearing articulations. There an accelerating wear is
performed.
Number of sprockets If there are more drive sprockets in a system, more frequently
the bearing will tend to articulate.
Number of teeth- the degree of articulation is much greater when the number of teeth
is less.
Chain length Shorter the length of the chain the fast the wear takes place
Lubrication Good wear life to happen the lubrication should be the right one.

The means of the bush and the pin is an essential combination to operate in conditions such
as static and mixed friction and also the lubrication is an important variable to consider in a
design system.

Chain Types

Engineering products should be of formal standards when it comes to the demand of an

industry. The transmission keys of certain chain standards are shown in the figure below. The
chain we used in our project is the chain used in modern bicycles. The specification is 1.5
inch of pitch, and the ANSI standard #40, where the roller diameter is 7.9 mm chain. In the
diagram below the simplex chain is the one we used.

Gear Figure 12: Different types of chains train

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The gear train is essential as using the gears; the motor speed (output of the motor) should be
reduced to match the speed of the wheels. The ratio of the gear should be chosen properly to
use motor and the batteries at their most effective point (Gardner 2014:9). The speed ratio is
important as well and the axes of shafts positions determined what type of gear trains used.
Gears used can be as of sprockets, helical or spur. The gear trains mostly applied are the
conventional belts. Other types of gear trains such as simple gear train and compound gear
trains can also be applied.

Simple gear train

There is only one gear on each shaft. From the transmit motion the gears are mesh with each
other from one shaft another. If the total distance against two gears are optimum. The motion
from one gear to the other can transmit by means of a gear having a larger size or it can
transmit by using intermediate gears. In most cases it is preferable to use idle gears as it
would inconvenience due to the increasing of the size of the gears can cause design flaws.

Figure 16: Simple gear train

Compound gear train

If there is more than one gear in the shaft the gear train is known as a compound gear train.
When the distance between two gears are fairly large, gears known as idle gears are used at

15
the same instant, this will cause the speed ratio to be much less as the compound gears are
used in intermediate shafts.

Figure 13: Compound Gear Train

In a simple gear train is known that it provides a large speed reduction, for this to happen the
last gear should be large enough. In compound gears to obtain a large speed reduction smaller
gears can be used.

Sprockets
The sprocket we used for our prototype is the 9T sprocket which is of 41 mm in diameter.
This sprocket is mounted on the motor and the 18 T sprockets which of 75 mm sprocket are
mounted to the rim of the wheelbarrow. The ratios of the sprockets are 2:1 ratio. The purpose
of obtaining these two sprockets is that it produces greater torque and has a lower speed.

Figure 14: 18T one way sprocket

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Figure 15: 9T Sprocket

POWER SYSTEMS

Motor Selections

A motor is defined as electrical energy converting to mechanical energy. There are two types
of motors. One is the DC (direct current) motors and the other is AC (alternating current)
motors. The major differences in these two motors are the magnetic field which is created.

The AC induction motor has no electrical connection. The stator in the AC voltage causes a
field to generate which in return affect the motor to turn. In a DC induction motor the
electrical connection through a brush and commutator has an impact on the rotor. (Kimbrell
2015:2)

There were two types of motors selected in our project. One is the fuel operated motor and
the other is the DC motor. The motor which our team used for the project was a DC motor.
The motor uses current from the batteries and makes the motor rotate. The motor
specification of the following is shown in the figure below.

Fuel operated motor

The fuel operated motor is a type of internal combustion engine which burn gasoline for fuel.
The ignition system uses a spark that generated a electric spark with the help of spark plugs
which ignites the fuel and the air which is inside the cylinder produces a fuel combustion.
The resulting fuel is heated and it is expanded in the cylinder which in return generated
mechanical energy.

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In fuel operated engine, the air and the fuel in the chamber is premixed before compression
occurs. This is the difference between a diesel engine and a gasoline engine. Another type of
gasoline engine is that the air is compressed first and the resulting fuel is added at the last part
of the compression stroke.

Figure 16: Fuel Operated Motor

Table 2: Specification of Gasoline Motor

Electric motor
An electric motor is basically an electric machine where the electric energy is converted into
mechanical energy. In normal situations of motoring mode, electric motors tend to operate
through electric motors winding currents and magnetic field to generate a force from the
motor. In cases like traction motors they can operate in means of both generating and
motoring modes to product energy by electrical and convert it to mechanical energy. Electric
motors have the tendency of producing torque (rotary force) and should be distinguished
from magnetic solenoid our any loudspeakers which could convert electricity into motion.

In our project we decided to go with the electric motor. The figure below shows what kind of
electric motor we used. The specification of the motor was MY1016z2 which is powered of
250w and the voltage is 24 V

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Figure 17: Selected motor

Dimensions

The dimensions of the motor are shown below. The reason to check for the dimensions is that
to check whether it will fit into the size of the wheelbarrow. We did not select the fuel
operated motor is because it is to big to fit it inside a wheelbarrow and be powered.

Figure 18: Dimensions of the MYZ1016Z2 motor

Performance of the motor

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Figure 19: Performance graph of motor

According to the catalogue, these are the specification from the supplier, which will ensure
that the weight can be supported on to the wheelbarrow or not.

Table 3: Performance values of the Motor

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Table 4: Specification of Motor

Battery
There were two batteries chosen for the project, but was taken building the prototype. The
two batteries were DC lead acid battery and the DC lithium battery. However the DC lead
acid battery was chosen for our final prototype.

Figure 20: Lead Acid

Battery

Figure 21: Lithium battery

However the DC lead acid battery was chosen for our final prototype. The specification of the
battery is known as Zeta 2.2Ah 12V DC Sealed Lead Acid Battery (Z20201). All the batteries
are of 12 volts batteries which is VDS approved. This means that the batteries are essential
for a 24 volt system. It is very important to choose a valid battery size for the current system,
so that the required standby time of 24 to 48 hours can be maintained.

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Technical specification from the supplier

Part No. : Z20201

Voltage : 12V DC
Capacity : 2.2Ah
Size (WxDxHmm) : 178x34x65
Weight : 1.0kg
Approvals : VDS Approved

DESIGN TERMINOLOGIES AND METHODS

The creation of ideas, understanding problems, solving problems and having a final solution
is a form of design process. Using the correct solution focus strategies the designing
terminologies can be processed and can be narrowed down.

Framing

Framing is important when the problem you are encountering is not clear. The purpose of
framing is to identify the actual problem and then converting that problem into a solution.

Design Processes

A Descriptive model

The purpose of a descriptive model is to demonstrate how a system functions and how the
designing process of that system works. The figure below shows the 4 stage which solely
describe the sequence of the activities in a final design process.

Figure 22: Descriptive Model

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 B Prescriptive model

A prescriptive model is a procedure where the solving of problems is done by an algorithmic

procedure. This method of solving is used when the problems are very complex in the design
system. The stages which represent the prescriptive model are shown below

Figure 23: Prescriptive Model

C Integrative model

In this model the solutions and errors are simultaneously explored and developed. For
instance, if a problem is come across and the solution is solved instantly, there will be a time
where the problem would be modified. This model is much easier to link solutions and
problems using this method.

Design methods
The two main methods are rational method and creative method.

Rational method Check list: Expresses what exactly to be done and how to
formalize the system or process
Creative method Brainstorming: Improving ideas by forming as a team.

Both of these methods tend use group work for decision making.

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Morphological charts

By using this chart the search for new solutions and alternatives can be broadened. There are
four major steps involved in a morphological chart.

1 List the functions or features that are important to the model of the wheelbarrow
2 For each feature of the desired function, list the means how it can be achieved.
3 Chart should be drawn to investigate all possible solutions.
4 Identify possible combinations of sub- solutions.

Figure 24: Example of morphological chart for a vegetable collection method.

Weighted objectives

Alternative solutions will be developed since the morphological chart is present. To choose
the optimum solution the weighted objectives process is very useful. The purpose of weighted
objectives is to compare and assess alternative design. The utility values of the contrast
design of the different proposals are the importance of the weighted object. The comparison
is mainly done by comparing the total performance against the weighted objectives. To set up
weighted objectives, the steps below show the procedure.

1 The design objectives should be listed

2 The list of objectives should be of rand order
3 Objectives should be assigned by relative weightings
4 Each objectives should have performance values and utility scores
5 Compare and then calculate the relative utility for the different designs

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Figure 25: Example for weighted objectives

Decision based off theory

Since welding cannot be done due to the thickness of the rim. A support is made by using
lathe machine and placed inside the rim, in order to hold the sprockets by welding.

Figure 26: Rim Support

25
Figure 27: Sprocket-rim assembly

Steel plate is installed between the wheelbarrow basin and the leg support. This is done to
mount the DC motor and to avoid modification to the original design of the bucket of the
wheelbarrow.

Figure 28: Motor mounted under the bucket of wheel barrow

26
Steel plate bracket is installed to hold the battery. The battery can be improved by using wood
material to avoid short circuit.

Figure 29: Batteries bracket

3. Concept Generation and Concept Selection

3.1 Concept Generation

In the project design process, the group will go through two types of review which is the
concept generation and concept selection. In the concept generation, first of all the team are
required to analyse the required objective of the project. After that, the team will go through
brainstorming session in order to come up as many concepts as we can that satisfied the
objective required in the project. Thus, each of the members has to come up with several
ideas of design based on requirement that analysed. However, there will be only one concept
will be selected as the final prototype. Concept selection process allows the team to evaluate
which concept is satisfying the objective. In the process, the team will evaluate the ideas by
using the concept scoring table to select the final concept for our project.

Morphological chart is a systematic and analytical method to generate idea. Through this
method, the idea generation can be accomplished by creating a system with similar feature
but from different mechanisms. First of all, the various features or functions of the product
are listed out based on the product requirement. Thus, generate few options of solution
regarding to every different features that are listed. Construct a chart that including the
various features as well as the solutions. Lastly, feasible solution can be determined by
analysing and combining the various options listed in the chart in order to obtain the final

27
solutions of the product. The chart shown below is the Morphological Chart for this
Motorized Wheelbarrow Project.

3.1.1 Morphological Chart and the Selection Outcome

Feature Option 1 Option 2 Option 3

Buy from
Wheelbarrow Self-made
manufacturer

Transmission Belt Drive Chain Drive

Type of wheel Pneumatic Tire Solid Rubber Tire

No. of wheel 1 2 4
12V DC Sealed
24v Lithium Ion
Battery Lead-Acid
Battery
Battery
Throttle Speed Basic on/off
Power System
Controller switch

Series and
Battery Configuration Parallel Series
Parallel
One Way Split Taper
Sprockets Double Pitch
Sprockets Bushed
Table 5: Model Selection 1 (Word in red is the selected option)

Feature Option 1 Option 2 Option 3

Buy from
Wheelbarrow Self-made
manufacture

Transmission Belt Drive Chain Drive

28
 Type of wheel Pneumatic Tire Solid Rubber Tire

No. of wheel 1 2 4
12V DC Sealed
24v Lithium Ion
Battery Lead-Acid
Battery
Battery
Throttle Speed Basic on/off
Power System
Controller switch

Series and
Battery Configuration Parallel Series
Parallel
One Way Split Taper
Sprockets Double Pitch
Sprockets Bushed
Table 6: Model Selection 2 (Word in red is the selected option)

Feature Model Selected 1 Model Selected 2

Buy from
Wheelbarrow Self-made
manufacture

Transmission Chain Drive Chain Drive

Type of Wheel Solid Rubber Tire Pneumatic Tire

No. of Wheel 1 2

12V DC Sealed Lead- 24v Lithium Ion

Battery
Acid Battery Battery

Throttle Speed Throttle Speed

Power System
Controller Controller

Battery
Series Parallel
Configuration

Sprockets One Way Sprockets Split Taper Bushed

Table 7: Selection Outcome

Based on the selected outcome for 2 models above, both conceptual models have been
selected to use the chain drive for the transmission system. However, other than Throttle
speed controller, the team could use an on-off switch as an alternative for the power system in
the project. As for the battery, there are choices between the Lithium Ion battery for model 2

29
and the lead acid battery for model 1. Furthermore, the wheelbarrow would either be bought
from the manufacture for model 1 or self-construct for model 2. The wheel for model 1 is
using the Solid rubber tire as the team choose to buy the whole wheelbarrow from
manufacture. However, pneumatic tire is selected in the model 2. As for the connection for
battery, the configuration for battery has been set to series for model 1 and parallel for model
2.

3.1.2 Weighted Objectives

This weighted objective is to evaluate and to determine which design would be the final
selection for this project based on the 2 models selected above. Both models will go through
an evaluation based on the criteria and its specific weightage in percentage that shown in the
table below:

Criteria Description Weightage (%)

Meet the requirement of the project 25
Performance
able to withstand in the test run 18
Durability
Easier in building phase 20
Ease of assembly
Minimize the cost used 15
Cost
Avoid injuries 15
Safety
Convenient in installation 7
Weight
Total 100
Table 8: Table of Criteria and its Description

30
Based on the criteria shown in the table 8 above, the selected model will be ranked
accordingly to its priority based on different criteria and the weighted score will be calculate
in order to determine which model has the higher weighted score according to different
criteria above. The final outcome is shown in the table below:

Weightage Model Selected 1 Model Selected 2

Criteria
(%)
Rating Weighted Score Rating Weighted Score
5 1.25 4 1.00
Performance 25
4 0.72 4 0.72
Durability 18
5 1.00 3 0.60
Ease of assembly 20
3 0.45 2 0.30
Cost 15
3 0.45 3 0.45
Safety 15
2 0.14 2 0.07
Weight 7
22 4.01 18 3.14
Total
1 2
Overall Rank
Table 9: Table of Weighted Objective

31
3.2 Concept Selection

Throughout the evaluation, the team has decided to choose the Model 1 as the selected
outcome because it achieves higher weighted score comparing to Model 2.

Wheelbarrow: Due to limited timeline given in the Project, the team would not have enough
time to build a whole wheelbarrow in the given period. In order complete the project in time,
the team decided to buy a whole new wheelbarrow from manufacture and transform it to a
motorized wheelbarrow by doing modification on it. Hence the modification work will be
done in a workshop site because certain tools and equipment are required during the
modification.

Transmission: Both models are decided to use the chain drive system as the DC motor
provided from the lecturer is function with the chain system. Furthermore, a chain that is
suitable to fit the gear teeth at the DC motor also provided. As the chain provided are slightly
longer than we need, thus we had used shorten the length so it could fit nicely to the gear
teeth and the sprockets.

Type of Wheel: Solid rubber tire is used in this project. Mainly because the solid rubber tire
come together with the wheelbarrow bought so the team is able to save cost of getting the
alternative tire. Although the tire is heavy than the pneumatic tire, but it do not go flat and
most importantly it is maintenance free. However, this type of tire able to withstand

32
punctures and debris. As the objective of this project is test run with a 20kg object, this tire is
able to achieve the criteria.

Number of Wheel: The team has decided to use one tire only in the project because a two
wheel design will need longer time on modification from the wheelbarrow bought. However,
one wheel design is more versatile in manoeuvring small places

Battery and its configuration: In this project, two sets of 12V DC Sealed Lead-Acid Battery
are used. Both type of battery mentioned in the morphological chart is provided from the
lecturer. However, the team had chosen to use the Lead-Acid battery mainly due to the
lithium battery required specific charger to charge and the team do not have a suitable
charger. As for the configuration of the battery, the team decided to connect the batteries in
series in order to add up the voltage of two batteries that allow reaching maximum input that
the motor required.

Power System: In the model selection 1, the team had decided to use the throttle speed
controller as the power system of the motorized wheelbarrow. Unfortunately, due to faulty of
the throttle speed controller, the team had replaced a simple on-off switch as the power
system in the project.

Sprockets: In this project, the team decided to use the one way sprocket. This type of sprocket
is basically same as the sprocket on the bicycles. The sprocket only transmits rotational
energy in one direction. The reason that the team choose this type of sprockets mainly
because of the sprocket is still able to rotate even if the motor stop functioning.

33
 4. The Design of Motorised Wheel Barrow
To design the motorised wheel barrow, first, we need to consider the total force required to
power up the wheel barrow. This first step is crucial as we need to select the motor that is
most suitable for the purpose. Then we will consider the battery and the transmission system
including the sprockets and chain, which were also equally important in creating a motorized
wheel barrow.

4.1 Motor Selection

Figure 30: The wheel barrow in 2D

The weight of the wheel barrow, ww = 15 k g 9.81=147.15 N

The weight of the load required to transport, wL = 20 kg 9.81=196.2 N

34
Total weight, wT 147.15+196.2=343.35 N

Diameter of wheel = 13inch = 0.3048m

Assume that the coefficient of kinetic friction, is 0.005,

The intended velocity for this wheel barrow is 0.5m/s, which will be achieved in 2.5
seconds.

The intended acceleration for this wheel barrow:

V 2V 1
Acceleration=
t

0.50

2.5

2
0.2 m / s

Required distance for the wheel barrow to reach 0.5m/s from rest with the acceleration

2
m
of 0.2 s :

2 2
V =U +2 as

0.52=0+2 ( 0.2 )( s )

Distance , s=0.625 m

m2
Force required to accelerate the wheel barrow at 0.2
s :

F=ma

35 0.2

35
 7 N

Power needed to for the wheel barrow to travel 0.625m in 2.5seconds.

d
Power=F
t

0.625
7
2.5

Nm
1.75
s

The minimum force needed to start to move the wheel barrow

F= W T

0.4 343.35

137.34 N

Power required for the wheel barrow to move at 0.5m/s:

Power=F V

137.34 0.5

68.67 W

Running torque:

T L =( mg ) ( D2 )
( 0.005 343.35 ) ( 0.3048
2 )
=0.26 N . m

Rotational Inertia of Wheel:

36
 1
I w = mr 2
2

0.3048 2

2
1 mass of wheel = 0.9kg, Diameter of wheel = 0.3048m
(0.9)
2

0.0104045 kg/m2

Angular Velocity when V = 0.5m/s:

=V /r

0.5

0.1524

3.28 rad /s

Angular Acceleration of wheel:

d
=
dt

3.28

2.5

2
1.312ra d /s

Torque by wheel rotational inertia:

T w =I

0.0101045 1.312

0.01365 N / m

37
Total torque required for the wheel Barrow:

Running Torque , T L +Torque by rotational inertia , T w

0.26+0.01365

0.27365 N / m

Since the ratio of sprocket is 9 teeth to 18 teeth, torque needed to be produced by motor
is:

9 Tm
=
18 0.27365 N /m

T m=0.136825 N /m

Based on the calculation for the torque needed for the motorised wheel barrow, we have
decided to go with MY1016Z2 electric DC motor.

Figure 31: MY1016Z2 DC Motor

Model MY1016Z2
Power 250W
Voltage 24V

38
Rated Rpm 3300RPM
Torque 0.8Nm
Table 10: Specification of the chosen motor

Based on the calculations stated previously and the specification of the motor, we can safely
deduce that the motors output is sufficient to be used for the wheelbarrow.

4.2 Transmission system

4.2.1 Sprockets

Figure 32: Motorised wheel barrow transmission

The sprockets setup used in the motorised wheel barrow is 9T attached to the motor, while
18T to the wheel. It was intended to operate the wheelbarrow at 0.5m/s. With a set of
calculation, we are able to find how many rounds per minutes will the sprocket attached to
the motor needs to turn in order achieve the velocity of 0.5m/s.

Speed Reduction Ratio:

9
r= =0.5
18

Rotational speed for wheel and its socket:

=V /r

0.5

0.1524

39
 3.28 rad /s

31.32rpm

Rotational speed for the motor and its socket:

18
=31.32
9

62.64 rpm

4.2.2 Chain
The sprockets used are a 9T and a 18T sprocket. Both of the sprockets are 10inches apart.

Figure 33: Chain system

The chain used to connect both sprockets is inch in pitch. With a set of calculations, we are
able to find how many links that are required for the chain and how long the chain will be.

Number of links:

T t 2
10
0.1013 =20
C = centre and centre of measured in pitch = 0.5
T+t
N=2 C+ +
2

40
 2
189

0.1013
T = teeth of sprocket 1; t = teeth of sprocket 2
18+ 9
2(20)+ +
2

53.6 54 links

Chain length:

L=Number of Links chain pitch

54 0.5

26.8 inches

0.68 metre

4.3 Batteries

Figure 34: Selected battery

The battery chosen for motorised wheel barrow is rated at 12V and 7Ah. Two of these
batteries will be used for the project and they will be connected in series so that they will give
an output of 24V which matches the motor rating of wheelbarrow.

Power rating of motor: 250W 24V

41
Rated speed of motor: 3300rpm

Required Speed for the wheel barrow:

18
=31.32
9

62.64 rpm

Power required for the motor to run at 62.64rpm:

62.64
Power=250 =4.74 W
3300

Power output by batteries connected in series:

Power=24 V 7 Ah=168Wh

Duration of operation:

168
Duration= =35.4 Hours
4.74

4.4 Wheel

Figure 35: Wheel of the wheel barrow

The diameter of the wheel chosen for the motorized wheel barrow is 13inch or 0.3302meter.

To find how much force is needed to climb over a curb, we can use the following equation.

42
Force required to climb over a curb:

2
rh

2
r

mg
F=

Where,

m = mass of the wheel barrow plus load

g = gravitational force

r = radius of wheel

h = height of the curb

Example,

Diameter of wheel=13 inch=0.3302 m

0.3302
Radius= =0.1651m
2

height of curb=0.05 m

mass of wheelbarrow plusload=15+20=35 kg

r h 2

2
r

mg
Force=

2
0.16510.05

2
0.1651
.
35(9.81)

43
 353.08 N

4.4 Prototype of the motorized wheel barrow

4.4.1 Wheel and Sprocket configuration
To drive the wheel of the motorized wheelbarrow, we have decided to mount a sprocket onto
one side of its rim as shown in the figure below. We have chosen a 18T one way sprocket to
be mounted to the wheel and 9T sprocket for the motor.

44
Figure 36: One Way Sprocket

The purpose of using a one way sprocket is to enable the wheel to spin freely in the forward
direction even when the motor is not operating. This is very important, particularly during the
situation where the wheelbarrow is moving down a slope where motor is not needed. Also,
with one way sprocket, we can reduce the risk of transmission damage to the motorized
wheel barrow.

However we have encountered a challenge while figuring out a way to mount the sprocket to
the wheel. Since the sprocket chosen is a one way sprocket, we were unable to drill some
holes and mount it to the rim with some bolts and nuts, as there are some moving mechanical
parts in the internal of the sprocket. Also, it was not possible to weld it onto the wheel,
because the excessively high heat of welding might damage rim of wheel which was already
very thin. Therefore we came out with a solution that is to fabricate a metal part to bridge the
sprocket and the rim. The metal part was created with a lathe machine according to the shape
of the rim, so that it could be bolted to the rim of the wheel. The metal piece can be seen in the
figure below.

45
Figure 37: metal part to be welded with sprocket and be bolted to the rim.

The sprocket was welded to the metal part, and the whole assembly was bolted to the rim of
the wheel as illustrated in the figure below.

Figure 38: One way sprocket welded to the rim

46
4.4.2 Motor
To mount the DC motor unto the wheelbarrow, we have decided to locate the motor under the
bucket of the wheel barrow. The motor was mounted under the bucket so that it will not
occupy any space in the bucket. We also planned to not drill holes or do any modification to
the bucket as we felt that do so might affect the practicality of the wheel barrow, especially
when transporting finer substances such as sand or cement. Thus we have made an additional
mounting rack according to the dimension of the wheel barrow. The rack was drilled with
holes according to the existing mounting area of the bucket, and then installed under the
bucket of the wheel barrow. Finally, the DC motor was installed to the mounting rack with
some sets of bolts and nuts. But before that, measurements were done to make sure that the
motor was aligned properly to ensure that the chain to connect both sprockets for motor and
wheel will not flex sideway. The configuration of motor is shown in the figure below.

Figure 39: Motor configuration

47
4.4.3 Chain
The chain that we have chosen has inch pitch, which is ANSI standard #40. Same as what a
modern bicycle is using. It has a tensile strength of 3125lb or 1417kg, which is strong enough
to operate the wheel barrow.

Figure 40: ANSI #40 Chain

It was important to determine the right length of the chain to ensure the longevity of the
chain. We did not want it to be too loose or over-tension, therefore, a series of calculation was
done to calculate the amount of links needed for the wheelbarrow. The length between two
sprockets and the number of teeth for both sprockets are considered in the calculation. For
this case, we needed 54 links of chain that totalled up to 0.68m.

Figure 41: Chain drive

48
4.4.4 Battery
Two DC 12V 7Ah batteries were chosen for the motorized wheel barrow. The batteries were
connected in series so that they formed an output of 24V to match the rated voltage of the
motor. To carry the batteries, we have fabricated a motor rack with some thin sheets of metal.
We mounted the battery pack to the back of the bucket of wheel barrow as we felt that it was
not ideal to place it inside the bucket of the wheel barrow as it would only occupy the space
and greatly reduce the amount of load that can be carried by the wheel barrow.

Figure 42: Batteries at the back of wheel barrow.

Besides that, we managed to place the battery as high as we could to prevent electrical shock
in wet conditions.

49
4.4.5 Electronic Speed Controller
Electronic speed controller was planned to be implemented to the motorised wheel controller.
We planned to include the speed controller in the wheel barrow so that we can regulate the
speed of the wheelbarrow for different condition and prevent sudden acceleration. Throttle
grip was supposed to be used to control the speed. However, the throttle grip we had received
was faulty; so we used an on/off switch instead.

Figure 43: Electronic Speed Controller and Throttle Grip

50
 5. Documentation
5.1 Solidworks Drawings

Figure 44: Top view of Wheel Barrow

Figure 45: Front View of Wheel barrow

51
Figure 46: Side View of Wheel Barrow

Figure 47: Isometric View of Wheel Barrow

52
Figure 48: Configuration of motor, sprockets and chain

Figure 49: Battery Placement and Throttle Grip

53
5.2 Electronic circuit Diagram of the Motorised Wheel Barrow

Figure 50: Configuration for the electronics

Figure 51: Circuit Diagram

This is the circuit diagram for the motorised wheel barrow. We connected the batteries in
series so that we can achieve total output of 24 volts, which was the maximum voltage the
motor can handle. The current flow will still be 7Ampere as it remains the same in series
configuration.

The power output of the batteries into the motor however, will be regulated by the speed
controller. As we turn the throttle, the speed controller will regulate the amount of voltage
flow according to how much we turn the throttle, thus controlling the speed of the motor.

54
 6. Conclusion
In a nutshell, after completing this project, the group has been given the opportunity to apply
the theory that they previously learn into actual project and product. Many practical skills
which are new to the group had been learned such as cutting metals, making holes, grinding
and lathe. These are used to help in completing the prototype. The challenges faced in the
group and the building of the prototype help the group to gain more experience in problem
solving, time management and mechanical system designing.

7. Recommendations
Although the wheel barrow built is running efficiently and able to carry required weight and
even more, there are still some drawbacks that required improvements to make it better. The
followings are the limitation and recommendation for it.

The absence of the speed control system, making the wheel barrow to run at full
speed. Thus, making it inconvenient when it is not loaded. A speed control system can
be added to control the speed manually.

Battery used. The battery used might not last long as required when the wheel barrow
is put to actual use. Battery can be changed in order to increase the working time.

The solid tire used has some drawbacks which it cannot absorb shock like pneumatic
tire. It would be harsh if the wheel barrow is worked on a bumpy or uneven surface. It
can be solved by substituting the solid tire with pneumatic tire.

Overall weight of the wheel barrow is relatively heavy due to the metal sheet added
for welding purpose in the process of mounting the motor. If the material of the wheel
barrow is change to a weldable material, the extra metal sheet can be removed.
Therefore, decrease the overall weight.

For the transmission chain, a cover can be added to prevent dust accumulating on the
chain and reduce the performance of the chain drive.

For the shaft at the wheel, chain and bearing, lubricant can be added to increase the
efficiency.

55
8. References
1. Wagner, K 2016, Powered Wheelbarrow, April 2013, Renold Roller Chain Catalogue,
Section 3 Designer Guide Specification Guideline.
2. Eng.fsu.edu, 2015, 'Idea Generation', viewed 2 October, 2015.
3. Kimbrell, J 2010, DC motors explained, Automation Direct, viewed 4 October, 2015, .
4. Fiegenbaum, T n.d., 'Series Circuits - Series Voltage Sources : Circuits - Electronics
Video Lecture', Allaboutcircuits.com, viewed 7 November, 2015,
<http://www.allaboutcircuits.com/video-lectures/series-circuits-series-voltage-
sources/>.
5. Oddparts.com, n.d., 'Overview Tutorial of Electric Motor Types', viewed 10
November, 2015,
<http://www.oddparts.com/acsi/motortut.htm#DC_MOTOR#DC_MOTOR>.
6. Brown, S 2008, "Gear Theory for Bicyclists", Sheldonbrown.com, viewed 24
November, 2016, <http://www.sheldonbrown.com/gear-theory.html>.
7. 2016, MY1016Z2-250W, 1st ed, ebikethaikit, Bangkok, pp. 1-3, viewed 24 November,
2016, <http://ebikethaikit.com/uploads/443/files/MY1016Z250W.pdf>.
8. Kok Heng, S 2016, "Systematic Design Tool", Lecture.
9. 2011, General Catalog 2012/2013, 1st ed, Oriental motor, Tokyo, pp. 1-25, viewed 24
November, 2016, <http://www.orientalmotor.com/products/pdfs/2012-
2013/X/usa_intro.pdf>.
10. 2016, "Chain specifications", Sprocketsunlimited.com, viewed 24 November, 2016,
<http://www.sprocketsunlimited.com/Chainspecifications.html>.
11. 2016, Tire and Wheel Theory, 61st ed, Cengage Learning, Delmar, pp. 1-25, viewed
24 November, 2016,
<http://www.cengage.com/resource_uploads/.../1111128618_276986.ppt>.

56
 week
9. Ap
NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 pe
1 ndi
2 x
3 Appendix
4
1 Gantt
chart
5

10

11

12

13

14

15

16

17

18

Table 11: Gantt Chart

57
NO. Task Description
1 Briefing of Design Project
2 Project group formation
3 Project Selection
4 Identifying design problems and constrains
5 Brainstorming and exploring design solution scope
6 Conceptual design of few alternatives to design solution
7 Evaluation of alternative conceptual alternative
8 Refinement of selected alternative
9 Detailed Design
10 Resources finding
11 Fabrication of models
12 Test Run
13 Refinements of models
14 Assessment on project models
15 submission of manual calculation for project model
16 Reflective essay submission
17 Preparation of report
18 Report submission
Table 12: Task Description

58
Appendix 2 Meeting minutes

Meeting minutes 1
3 September 2016

3.30pm

Venue:

Swinburne Cafeteria

Member Present:

Philip Chin Kai Wen

Don Kushan Wijemanne

Lim Yong Sheng

Kuek Pheck Ching

Objectives:

To discuss about the topic for the project

To discuss about the due dates for several submission

Project Progress:

The group is formed and topic of for the project is selected. The members are discussing
about the overall procedure for the project.

59
Meeting minutes 2
13 September 2016

Time:

2.30pm

Venue:

Swinburne Cafeteria

Member Present:

Philip Chin Kai Wen

Don Kushan Wijemanne

Lim Yong Sheng

Kuek Pheck Ching

Objectives:

To discuss about the design of the wheel barrow prototype

To discuss about acquiring the material for the prototype

To discuss about the understanding of the project among the group members

60
Meeting minutes 3
20 September 2016

Time:

1.30pm

Venue:

Local material store

Member Present:

Philip Chin Kai Wen

Don Kushan Wijemanne

Lim Yong Sheng

Kuek Pheck Ching

Objectives:

To survey the price for the parts needed for the project

61
Meeting minutes 4
20 September 2016

Time:

1.30pm

Venue:

Local material store

Member Present:

Philip Chin Kai Wen

Don Kushan Wijemanne

Lim Yong Sheng

Kuek Pheck Ching

Objectives:

To survey the stores and price for the parts needed for the project

62
Meeting minutes 5
22 September 2016

Time:

3.30pm

Venue:

Workshop to work with the project

Member Present:

Philip Chin Kai Wen

Don Kushan Wijemanne

Lim Yong Sheng

Kuek Pheck Ching

Objectives:

To discuss about how to build the prototype

To discuss about the modification to be made to install the parts for the prototype

Getting all the materials ready for building the prototype

Start building the prototype

Fabricating the parts needed to install the wheel

63
Meeting minutes 6
28 September 2016

Time:

3.30pm

Venue:

Workshop to work with the project

Member Present:

Philip Chin Kai Wen

Don Kushan Wijemanne

Lim Yong Sheng

Kuek Pheck Ching

Objectives:

To work on the mounting of the motor

64
Meeting minutes 7
5 October 2016

Time:

3.30pm

Venue:

Workshop to work with the project

Member Present:

Philip Chin Kai Wen

Don Kushan Wijemanne

Lim Yong Sheng

Kuek Pheck Ching

Objectives:

To do finishing on the prototype

Test run

Discuss about the report writing

Get the prototype ready for the test run

65
Meeting minutes 8
12 October 2016

Time:

3.30pm

Venue:

Swinburne

Member Present:

Philip Chin Kai Wen

Don Kushan Wijemanne

Lim Yong Sheng

Kuek Pheck Ching

Objectives:

Test run of the prototype

66
Meeting minutes 9
1 November 2016

Time:

6.30pm

Venue:

Swinburne Open Lab

Member Present:

Philip Chin Kai Wen

Don Kushan Wijemanne

Lim Yong Sheng

Kuek Pheck Ching

Objectives:

To prepare the slide for the presentation

To practice for the presentation

67
Meeting minutes 10
10 November 2016

Time:

230pm

Venue:

Swinburne Open Lab

Member Present:

Philip Chin Kai Wen

Don Kushan Wijemanne

Lim Yong Sheng

Kuek Pheck Ching

Objectives:

To update what has been done on the project for each group member

Distribute the task for each member in completing the report

68
Meeting minutes 11
23 November 2016

Time:

230pm

Venue:

Swinburne Open Lab

Member Present:

Philip Chin Kai Wen

Don Kushan Wijemanne

Lim Yong Sheng

Kuek Pheck Ching

Objectives:

Finishing the group report

Compilation of the group project

69
 Appendix 3 Safe Design
Failure Mode and Effect Analysis (FMEA) on the motorized wheel barrow

Severity
Potential Failure Mode
Function

Detection
Potential Effects of failure

Potential Causes of failure

Occurrence

Actions
How will the potential

RPN
Part

failure be detected
Wheel Allows the Bent or Wobbly 6 Vibration 3 Inspect 4 72 Replace
movement damaged operation from the the rim
wheel rim uneven rotation
barrow ground of the
wheel
motor Gives No Wheel will 3 No 5 Check 3 45 Charge
power to response not turn electricity the the
the wheel input batteries batteries
motor Gives Full Wheel will 8 Damaged 3 Check 4 120 Replace
power to Speed not stop speed the the speed
the wheel non stop turning at controller response controller
full speed of motor
Motor Gives No Wheel will 3 No 3 Check 6 54 Rewire
power to response not turn Electricity the the
the wheel input wiring system
Motor Gives No Wheel will 7 Damaged 2 Check 7 98 Replace
power to Respons not turn motor the the motor
the wheel e motor
Chain Transmit Broken Wheel will 4 Excessive 4 Check 3 48 Replace
energy Chain not turn load the chain the chain
from
motor to
wheel
Bucket To carry Deforma Reduced 5 Excessive 2 Check 3 30 Replace
of the loads tion carrying load the the bucket
Wheel capability bucket
Barrow
Wheel To support Deforma Unstable 6 Excessive 2 Check 4 48 Repair the
barrow the wheel tion operation load the leg leg
leg barrow support support
support assembly
Table 13: FMEA analysis

70