1.

Calculation for Pulling Force:

The maximum load carrying capacity of trolley- 70kg

Load of trolley assembly- 30kg

Therefore,

Total load- 100kg

Pulling Force = Total pulling + Tractive Effort

weight of
trolley

Fp = F + µR

Let maximum possible angle for stair be 45˚ ∴θ=45˚

∴ Fp = mgsin45˚+ µmgcos45˚

∴ Fp = 100*10*sin45˚ + 0.2*100*10*cos45˚

∴ Fp = 850N = 85kg

2. Calculation for torque and motor power:

T= Fp* 0.225 = 250*0.225 = 57Nm

P = T*ω
2𝜋𝑁
P=T* 60

2∗𝜋∗30
P= 57 * 60

∴ P = 176W
3. Calculation for shaft diameter:

A) For Equilibrium of forces

∑F= RA + RB = 250 + 250

∑MA= 250*70 + 250*630 – RB*700 = 0

∴ RA = 250N RB = 250N

B) Shear Force Diagram

SFA= 250N

SFB= 250 – 250 = 0

SFC= 0-250 = -250N

SFD= -250+250 = 0

C) Bending Moment Diagram

MA= 0

MB= 250*0.7 =17.5Nm

MC= 250*0.63 - 250*0.56 = 17.5 Nm

MD= 0 Nm

∴ Maximum Bending Moment (B.M.) = 17.5Nm

We have, B.M. = (π/32) * d3 * σb

For shaft material SAE1030, σyt = 296MPa

B.M. = (π/32)* d3 * (296/2)

17500 = (π/32)* d3 * (296/2)

∴ d= 10.63mm
4) Design of chain drive:

Velocity ratio of chain drive V.R. =N1/N2 = 60/30 =2

Number of teeth on smaller sprocket or pinion T1 =12

∴ Number of teeth on larger sprocket T2 = T1* (N1/N2) = 12*2 = 24

Design power= Rated power * service factor

= 176*1.875

=0.3KW

From Design Data Book by B.D. Shiwalkar, Fig. 14.1

∴ Pitch p = 12.7mm

Roller diameter dr =7.93mm

Chain width w=7.93mm

PCD of pinion d1= p*cosec (180/T1) = 49.06mm

PCD of larger sprocket d2= p*cosec (180/T2) = 97.29mm

Tri-Star Wheel Design

Deriving the Tri-Star wheel parameters depends on the position of Tri-Star wheel on stairs. It
depends on two parameters, the distance between the edge of wheel on lower stair and the face of
the next stair(L1), and the distance between the edge of wheel on topper stair and the face of next
stair (L2), as shown in Figure a.
By comparing these parameters, three states may occur as follow:

1. L1 < L2 2. L1 >L2 3. L1 = L2

Fig. a Fig. 2
Based on these states, the third states (L1 = L2) will be used as the reference of project to design
the Tri-Star wheel. In this case, the L1 and L2 don’t change and remain constant while climbing
stairs. Therefore the case (1) and case (2) are not suitable since the robot will encounter the
problems while climbing stairs, but the case (3) is suitable for climbing robot smoothly. It should
be noted that the value of L1 and L2 for derivation of the parameters maybe any values but
equal. L1 and L2 are assumed equal to the radius of angular wheel (L1=L2=r). In the design of
Tri-Star wheel, five parameters are important which are the heights of the stairs ( a ), width of
stairs ( b ), radius of regular wheel ( r ), radius of Tri-Star wheel, the distance between the centre
of Tri-Star wheel and the centre of its wheel ( R ) and the thickness of holders that fix the wheel
on its place on Tri-Star wheel ( 2t ), as shown in Figure 3.1b.

According to the project requirements, the value of (a) and (b) are determined as

a= 15s cm, b = 29 cm, r = 3.5cm

R=√ 2+ 2=√152+292= 18.85cm

3 3

The minimum value radius of regular wheel ( ) to prevent collision of the holders the stair is
derived as

6 + (3 6 18.484+15(3
+√3 ) 29+√3 15)
= 8.43
= = cm
(3−√3) (3−√3)15+(3+√3
+(3+√3) )29

The maximum value radius of the regular wheels ( ) to prevent the collision of the wheels
together is

= √ 2+ 2= √152+292= 23.08cm 2 2

The maximum value of the thickness of holders to avoid collision between the holders and stairs
is derived by
 (3−√3)+
(√3 (3+√3)+ −√3)

=
1 6 =
15 4(3−√3)+29 4(3+√3)+15(√3 15−√3 29)= 5.17 cm 6 18.85

For, knowing the amount of r and R, we can derive the maximum height of stairs that the robot
can pass through it

1 =√2+ 2 − 2= √152 + 292 − 42= 32.4037cm

For traversing the stairs with the maximum height, the half thickness of the holder must be in the
following range.

( +√3(2 + 2− 4(4+√3(15 2+2 =

=
2 2)) = 92−42)) 3.68cm