CHAPTER-1

INTRODUCTION

1.1. Hand Trolley

A hand trolley is a small transport device used to move heavy loads
from one place to another. It is a very common tool used by a large number
of industries that transport physical products. Also called a hand truck or a
dolly, the hand trolley is often used by stock persons who arrange and
restock merchandise in retail stores. When used properly, trolleys can
protect people from back injuries and other health problems that can result
from lifting heavy loads.

1.1.2. Description
A typical hand trolley consists of two small wheels located beneath a
load-bearing platform; the hand trolley usually has two handles on its
support frame. These handles are used to push, pull and maneuver the
device. The handles may extend from the top rear of the frame, or one
handle may curve from the back. An empty hand trolley usually stands
upright in an L-shape, and products are usually stacked on top of the
platform. When the goods are in place, it is tilted backward so that the load
is balanced between the platform and the support frame. Especially if heavy
or fragile materials are moved, the person operating the trolley should
return it to an upright position carefully, to insure nothing falls off the
platform. The front of the frame may be squared off for boxes or curved for
drums and barrels. Sometimes, a hand truck also has straps for securing
loose freight during transport.

Professional material handlers prefer to use a hand truck when

moving stackable items such as boxes, crates or packages. Heavier items
are usually stacked on the bottom of the hand truck, with lighter objects
saved for the top.

Hand truck users must be careful not to stack it so high that their
vision is blocked or the load becomes unstable. Generally, it is safe to load a

1
hand truck to the level of its handles or the top of the frame. The load is
then shifted onto the wheels with a backwards lifting motion. The user can
maneuver the cargo by steering it left, right or forward.

1.2. Types of Trolleys

Different types of these trolleys exist, and the type used is often
chosen based on what type of material it will move. Hand trolleys are made
of various types of hard materials, including steel, aluminum and high-
impact plastic. Most hand trolleys come in standard sizes and are used for
general loads, but there are some that are specifically designed for very
small or large products.

1.2.1. Wheeled Trolley

Wheeled trolleys made from stainless steel are the most common type
of hand trucks used. These are used in places with heavy loads to move, like
retail stores and factories, and typically have wheels made out of stainless
steel as well. Welded steel and metal wheel trolleys are typically much more
lightweight and are often used to carry lighter materials.

Those with a frame and wheels made of a metal alloy are heavier and
sturdily made. Trolleys of this type usually have a wider platform for
oversized loads. Metal alloy hand trucks are typically used to transport
heavy products, such as items made of steel.

1.2.2. Folding Trolley

A folding trolley is another type of hand tool, and is often made of
rust-proof aluminum. It is also lightweight but is usually able to carry heavy
loads, and can fold to take up less space when not in use. This feature also
allows it to be easily transported to places where it is needed.

1.2.3. Garden Trolley

The garden trolley is a man evener with the use of a pull handle.
Garden trolleys tend to have narrow profiles so that they will fit easily on
paths and walks without damaging plants. These are designed so that they

2
are capable of lifting both dry and marshy loads which are most commonly
found in gardens.

1.2.4. Kitchen Trolley

A kitchen trolley is a serving cart that can also be used for storage. It
is designed that it has more than one section in it which enables people to
carry various utensils and for various purposes.

1.2.5. Sack Trolley

Sack trolley or Sack barrow is a fairly generic term describing a range
of light, single operator hand trucks or trolleys used to move cartons, feed
and grain sacks, and other light, stackable goods. Lots of different materials
are used to make sack trucks. This includes high impact plastics, tube
steel, aluminum steel, and aluminum excursion.

1.3. Need For Stair Climber Trolley

Lifting heavy objects to upper stories or lifting patients to upper levels
from the ground are not painless jobs, especially where there are no lifting
facilities (elevator, conveyer, etc.). Moreover, most of the buildings are
structurally congested and do not have elevators or escalators. This project
can introduce a new option for the transportation of loads over the stairs.
The stair climbing hand trolley can play an important role in those areas to
lift loads over a short height.

1.3.1. Stair Climber Trolley

The stair-climbing hand truck is designed to reduce liability rather
than increase it. Conventional hand trucks work well on flat ground, but
their usefulness decreases when it becomes necessary to move an object
over an irregular surface. Package deliverymen, for example, often find it
necessary to drag loaded hand trucks up short flights of stairs just to reach
the front door of a building. The entire purpose of using a conventional
hand truck is to avoid having to lift and carry heavy objects around.

3
 Lifting a hand truck up the stairs defeats the purpose of the device,
since the user must provide enough upward force to lift the entire weight of
the cart and its contents. Furthermore, the geometry of a hand truck makes
it nearly impossible to lift with one's legs, as is the proper form.
Considerable strain is placed on the back muscles and the risk of operator
injury is sharply increased. The pulling up of a standard hand truck up the
stairs results in a bumpy and jarring motion. This motion may damage the
items loaded on the hand truck or cause them to fall off entirely. A hand
truck that could climb stairs without requiring the user to lift would
improve the safety of moving heavy objects over irregular surfaces.

In our project, we are designing and fabricating normal hand trolleys

with Tri-Star wheel in order to enable the trolley to move up or down the
stairs.

1.3.2. Components
• Wheels
• Bearings
• Connecting Rods
• Goods Holder Frame
• Handle Rods
• Connecting Rods
• Support Rods
• Mounts & Brackets
• Supporting Frame
• Joints & Screws

1.3.3. Advantages:
• Easy Vertical Transportation
• Smart Approach
• Material Transport in Buildings
• More number of items are carry at a time
• Less effect to carry goods
• Works on both flat & staircases surfaces

1.3.4. Disadvantages:

4
 • This is not suitable for all type of stairs
• The load is not excited to more than half ton
• Load increases with the applying force also increases
• Because there is no visual barrier between the two floors connected by
a straight staircase

1.3.5. Block Diagram Stair Case Climbing Trolley

Fig 1.3.5. Blok diagram of stair case climbing trolley

5
 CHAPTER-2
LITERATURE REVIEW

In the paper titled, “DESIGN AND FABRICATION OF STAIR CLIMBING

TROLLEY”,[1].

Trolley is generally use for the carrying heavy weights with the help of less
human effort. The manufacturing of the trolley deals with proper design,
accurate fabrication and prescribed analysis using finite element software
gives better motion which resists to high load by applying less effort this
paper deals with manufacturing of such stair climbing trolley with simple
mechanism.

In the paper titled, “Stair Climbing Hand Trolley”,[2].

A hand truck with the ability to climb stairs would decrease the possibility
of injury from having to lift a wheeled cart or its contents over an
obstruction. If successful, this device should provide increased safety both
in the home and in the workplace. Also, it is hoped that a simple stair-
climbing device such as this one might increase public acceptance of other,
more complex stair-climbing devices such as wheelchairs.

In the paper titled, “DESIGN AND FABRICATION OF STAIR CLIMBING

TROLLEY”,[3].

This project aims at making headway for developing a mechanism for

transportation of considerable loads over stairs. The requirement for such a
trolley emerges from everyday prerequisites in our general public. Hand
trolleys are used to lessen the stress of lifting while moving it on flat ground;
however, these hand trolley usually fail when it comes to shifting the load
over stairs.

6
In the paper titled, “Automatic Stair Climbing Trolley”,[4].

This project aims at developing a mechanism for easy transportation of

heavy loads over stairs. The need for such a system arises from day-to-day
requirements in our society.however, these devices usually fail when it
comes to carrying the load over short fleet of stairs. In the light of this, the
project attempts to design a stair climbing hand cart which can carry heavy
objects up the stairs with less effort compared to carrying the manually.

7
 CHAPTER-3
DESIGN

3.1. Tri- Wheel Design

The Tri-wheel was designed in 1967 by Robert and John
Forsyth of the Lockheed Aircraft Corporation. They were first developed as a
module of the Lockheed Terrastar, a commercially unsuccessful amphibious
military vehicle. A Tri-Star wheel functions as an ordinary wheel on flat
ground, but has the ability to climb automatically when an impediment to
rolling is encountered. This wheel design consists of three tires, each
mounted to a separate shaft. These shafts are located at the vertices of an
equilateral triangle. The three shafts are geared to a fourth, central shaft (to
which a motor may be attached). When geared in this quasi-planetary
fashion, these triangular sets of wheels can negotiate many types of terrain,
including sand and mud; they can also allow a vehicle to climb over small
obstructions such as rocks, holes, and stairs. The wheel assembly may be
gear-driven, with two wheels in rolling contact with the ground. The third
wheel idles at the top until the lower front wheel hits an obstruction. The
obstruction prevents the lower front wheel from moving forward but does
not affect the motion of the driving axle. This causes the top wheel to roll
forward into position as the new front wheel. This wheel usually lands on
top of the obstruction and allows the rest of the assembly to vault over the
obstruction.

Fig.3.1. TRI-WHEEL
3.2. Application Of Tri-Star Wheel In Our Project

Fig.3.1. Wheel movement on flat surfaces

In our project, we are using this Tri- wheel arrangement in a

hand trolley in the place of normal wheels setup to enable the trolley to
climb up and down the stair cases and also to up come small obstacles like
holes and bumps on its path.

Fig.3.2. Wheel movement on staircase surface

3.3. Selection and Fabrication of Stair Climber Trolley

3.3.1. Material Selection
Material selection is a step in the process of designing any
physical object. In the context of product design, the main goal of material
selection is to minimize cost while meeting product performance goals.
Systematic selection of the best material for a given application begins with
properties and costs of candidate materials.

3.3.2. Trolley Body (Mild Steel)

Mild steel, also called as plain-carbon steel, is the most
common form of steel because its price is relatively low while it provides
material properties that are acceptable for many applications, more so than
iron. Low-carbon steel contains approximately 0.05–0.3% carbon making it
malleable and ductile. Mild steel has a relatively low tensile strength, but it
is cheap and malleable; surface hardness can be increased through
carburizing. It is often used when large quantities of steel are needed, for
example as structural steel. The density of mild steel is approximately 7850
kg/cm3 and the Young's modulus is 210 GPa (30,000,000 psi).

3.3.3. Tri-Star Wheel Hub (Stainless Steel Grade 304):

Steel Type 304 is a variation of the basic 18-8 grade, Type
302, with a higher chromium and lower carbon content. Lower carbon
minimizes chromium
Carbide precipitation due to welding and its susceptibility to
inter-granular corrosion. In many instances, it can be used in the “as-
welded” condition, while Type 302 must be annealed in order to retain
adequate corrosion resistance. Type 304L is an extra low-carbon variation of
Type 304 with a 0.03% maximum carbon content that eliminates carbide
precipitation due to welding. As a result, this alloy can be used in the” as-
welded “condition, even in severe corrosive conditions. It often eliminates
the necessity of annealing weld mints except for applications specifying
stress relief. It has slightly lower mechanical properties than Type 304.

3.4. Bearing Selection

Ball Bearing
A ball bearing is a type of rolling-element bearing that uses
balls to maintain the separation between the bearing races. The purpose of
a ball bearing is to reduce rotational friction and support radial and axial
loads. It achieves this by using at least two races to contain the balls and
transmit the loads through the balls. In most applications, one race is
stationary and the other is attached to the rotating assembly. As one of the
bearing races rotates it causes the balls to rotate as well. Because the balls
are rolling they have a much lower coefficient of friction than if two flat
surfaces were sliding against each other.
Selecting a ball bearing with minimum inner diameter of 20mm,
minimum load carrying capacity of 50kg radially and speed greater than
50rpm.

3.4.1. Bearing Selected - Skf 6006 Open Deep

Groove Ball Bearing:
Inside radius : 12mm
Outside radius : 25mm
Width : 13mm
This 6006-2RS 12x35x13-millimeter sealed ball bearing
has deep groove geometry for high speeds and supporting both radial and
axial loads. This bearing has rubber seals on both sides of the bearing to
keep lubricant in and contaminants out, and comes pre-lubricated from the
manufacturer so that no additional lubrication is required. This deep groove
sealed ball bearing is for use in applications that involve combined radial
and axial loads, and a need for high running accuracy at high rotational
speeds. Such applications include clutches, drives, gearboxes, compressors,
pumps, turbines, and printing and textile machines, among others.
 Fig 3.4.1. Bearing

3.5. Wheel Selection

3.5.1. Filled Rubbers
In tyres rubbers are usually filled with particles like carbon
black or silica. They consist of a tread and a body. The tread is the part of
the tire that comes in contact with the road surface. The portion that is in
contact with the road at a given instant in time is the contact. Treads are
often designed to meet specific product marketing positions.

3.5.2. Polyurethane
Polyurethane (PUR and PU) is a polymer composed of a
chain of organic units joined by carbamate (urethane) links. While most
polyurethanes are thermosetting polymers that do not melt when heated,
thermoplastic polyurethanes are also available. The main ingredients to
make a polyurethane are isocyanates and polyols. Other materials are added
to help processing the polymer or to change the properties of the polymer.

3.5.3. Steel
Steel is an alloy of iron, with carbon being the primary
alloying element, up to 2.1% by weight. Carbon, other elements, and
inclusions within iron act as hardening agents that prevent the movement
of dislocations that naturally exist in the iron atom crystal lattices.

3.5.4. Static Friction

The surface of the wheel and what it is rolling on are not perfectly
smooth. They have irregularities shown in figure
 Fig 3.5: Close-up of wheel surface

3.6. Close-Up Showing Surface Roughness

In sliding friction, this surface roughness is the reason for
the static and kinetic resistance to motion. Although the wheel is not
sliding, the surface roughness causes a "jiggle" when the wheel is rolling.

3.7. Various Wheel Materials And Their Co-Efficient Of

Frictions
Various Wheel materials and their co-efficient of frictions are tabulated in
table and shown graphically in figure

S. No. Material Coefficient of friction

1 Rubber/concrete 0.85
2 Polyurethane/Concrete 0.5
3 Steel/Concrete 0.45
Table: 3.7. Various Wheel Materials and their Coefficient of friction

Coefficient of kinetic friction of various tyre materials and concrete surface

3.8. Wheel Frame

A specially designed wheel frame is required to hold the three
wheels together on each side of the shaft. In the existing design, the power
transmission to the single or double wheel trolley is useless to climb the
stairs due to height factor of stairs. The design of the straight wheel frame
became more complicated and was needed to be modified with its curved-
spherical shape to give proper drive, which creates more frictional force. For
these reason, three wheel set on each side of vehicle attached with frame
was introduced to provide smooth power transmission in order to climb
stairs without much difficulty. Frame arrangement is suitable to transmit
exact velocity ratio also. It provided higher efficiency and compact layout
with reliable service. Easier maintenance was possible in case of replacing
any defective parts such as nut, bolt, washer, etc.

Fig:3.8. Wheel Frame

3.9. Types Of Wheel Frames

A few types of wheel frames are shown in the figure

.
Fig 3.9.1: Straight Wheel Frame

Fig 3.9.2: Curved Wheel Frame

 Fig 3.9.3: Quasi Planetary Wheel Frame
We are selecting to our project as frame straight wheel frame

3.10. Inference
After its fabrication, we inferred few limitations like large noise production
while moving the trolley up and down the stairs. In order to reduce the noise
production the design of the wheel frame is to be modified such that line
passing through the mid-point of the trolley wheel should pass through the
mid-point of the step. The modified wheel CAD model is shown in figure

Fig 3.10: Modified Wheel Frame Setup

 CHAPTER-4

INTRODUCTION DESIGN SOFTWARE CATIA-V5

Computer-aided three-dimensional interactive application) is a multi-

platform software suite for computer-aided design (CAD), computer-aided
manufacturing (CAM), computer-aided engineering (CAE), PLM and 3D,
developed by the French company Dassault Systèm.

4.1. History
CATIA started as an in-house development in 1977 by French aircraft
manufacturer AVIONS MARCEL DASSAULT, at that time customer of the
CADAM software[1] to develop Dassault's Mirage fighter jet. It was later
adopted by the aerospace, automotive, shipbuilding, and other industries.
Initially named CATI (conception assistée tridimensionnelle interactive
– French for interactive aided three-dimensional design), it was renamed
CATIA in 1981 when Dassault created a subsidiary to develop and sell the
software and signed a non-exclusive distribution agreement with IBM.
In November 2010, Dassault Systems launched CATIA V6R2011x, the
latest release of its PLM2.0 platform, while continuing to support and
improve its CATIA V5 software.
In June 2011, Dassault Systems launched V6 R2012.
In 2012, Dassault Systems launched V6 2013x.
In 2014, Dassault Systems launched 3DEXPERIENCE Platform
R2014x [10] and CATIA on the Cloud, a cloud version of its software.

4.2. Scope Of Application

Commonly referred to as a 3D Product Lifecycle Management software
suite, CATIA supports multiple stages of product development (CAx),
including conceptualization, design (CAD), engineering (CAE) and
manufacturing (CAM). CATIA facilitates collaborative engineering across
disciplines around its 3DEXPERIENCE platform, including surfacing &
shape design, electrical, fluid and electronic systems design, mechanical
engineering and systems engineering.
 CATIA facilitates the design of electronic, electrical, and
distributed systems such as fluid and HVAC systems, all the way to the
production of documentation for manufacturing.

4.2.1. Mechanical Engineering

CATIA enables the creation of 3D parts, from 2D sketches, sheet
metal, composites, and molded, forged or tooling parts up to the definition of
mechanical assemblies. The software provides advanced technologies for
mechanical surfacing & BIW. It provides tools to complete product
definition, including functional tolerances as well as kinematics definition.
CATIA provides a wide range of applications for tooling design, for both
generic tooling and mold & die. In the case of Aerospace engineering an
additional module named the aerospace sheet metal design offers the user
combine the capabilities of generative sheet metal design and generative
surface design.

4.2.2. Design
CATIA offers a solution to shape design, styling, surfacing
workflow and visualization to create, modify and validate complex innovative
shapes from industrial design to Class-A surfacing with the ICEM surfacing
technologies. CATIA supports multiple stages of product design whether
started from scratch or from 2D sketches (blueprints).

4.2.3. Industries
CATIA can be applied to a wide variety of industries, from
aerospace and defense, automotive, and industrial equipment, to high tech,
shipbuilding, consumer goods, plant design, consumer packaged goods, life
sciences, architecture and construction, process power and petroleum, and
services. CATIA V4, CATIA V5, Pro/ENGINEER, NX (formerly Unigraphics),
and Dassault Systems' own Solid Works platform are the dominant systems.

4.3. File Compatibility and CATIA V4 /V5 /V6 Conversion

Dassault Systems provides utilities to convert CATIA V4 data
files so they are accessible to CATIA V5 and CATIA V6. Still, cases show that
there can be issues in the data conversion from CATIA V4 to V5 from either
difference in the geometric kernel between CATIA V4 and CATIA V5 or by the
modeling methods employed by end users. The percentage loss can be
minimized by using the appropriate pre-conversion clean-up, choosing the
appropriate conversion options, and clean-up activities after conversion.

Conversion from CATIA Version 4 to Version 5 created construction

problems for the Airbus A380 aircraft. These problems resulted in $6.1B of
additional costs due to years of project delays when aircraft wiring was too
short to make connections.

Transition from V5 to V6 is facilitated because they are sharing the

same geometric kernel. Third-party file translators also up-convert CATIA
files between versions.

Competition
CATIA competes in the high-end CAD/CAM/CAE market with Siemens NX.

4.4. Basic Commands To Catia V5

4.4.1. Specification Tree
4.4.2. Mouse Controls

4.4.3. View Toolbar

4.4.4. Other Commonly Used Tools:

4.4.5. Sketcher Module:

The Sketcher workbench is a set of tools that helps you create and
constrain 2D geometries. Features (pads, pockets, shafts, etc...) may then be
created solids or modifications to solids using these 2D profiles. You can
access the Sketcher workbench in many ways. Two simple ways are by
using the top pull down menu (Start – Mechanical Design – Sketcher), or by
selecting the Sketcher icon. When you enter the sketcher, CATIA requires
that you choose a plane to sketch on. You can choose this plane either
before or after you select the Sketcher icon. To exit the sketcher, select the
Exit Workbench icon.
The Sketcher workbench contains the following standard workbench
specific toolbars.
• Profile Toolbar: The commands located in this toolbar allow you to
create simple geometries (rectangle, circle, line, etc...) and more complex
geometries (profile, spine, etc...).
• operation toolbar: Once a profile has been created, it can be modified
using commands such as trim, mirror, chamfer, and other commands
located in the Operation toolbar.
• Constraint Toolbar: Profiles may be constrained with dimensional
(distances, angles, etc...) or geometrical (tangent, parallel, etc...) constraints
using the commands located in the Constraint toolbar.
• Sketch Tools Toolbar: The commands in this toolbar allow you to
work in different modes which make sketching easier.

Part Design Module

Part design environment is used to create 3D models from the basic
2D sketches created in sketcher environment.
Some of the commands in workbench explained below

Pad Command
In most CAD software, the equivalent of this is called EXTRUDE, but
in CATIA we call it PAD. This command adds material in the third direction,
a direction other than the sketch.

Fig 4.4.5.1: Pad command

Pocket Command
The POCKET commands somehow the opposite of PAD command. It
simply helps remove geometry belonging to an already create part. On the
figure below the POCKET command is helping to create the cylinder hole in
the middle of the cube.
 Fig 4.4.5.2. Pocket command
Shaft Command
It is like revolve command in other CAD software, the SHAFT
command is mostly used to make shaft like parts. It requires an axis,
around which the sketch will be resolved.

Fig 4.4.5.3: Shaft command

Rib Command
This command which is usually known as SWEEP is called RIB IN
CATIA. It adds material along a guide curve. RIB is used to make
components like springs, pipes etc.
 Fig 4.4.5.4. Rib command

Slot Command
SLOT removes the material along a guide curve. Here is an example of
slot. While using SLOT, I have used the same guide curve that was used for
RIB. This ensures that the cross section will be uniform throughout.

Fig 4.4.5.5. Slot command

4.5. Step 4: Assembly Module
Assembly environment is used to provide mating to two or more part
models to from complete assembly
We have two approaches in assembly
 Top -down approach
 Bottom -up approach
Entire design structure will be created in product environment in Top -
down approach whereas in bottom - up parts will be created separately and
will be mated using mating or constraint tools.

4.6. Step 5: Drafting Module

Drafting is a process of generating 2D machine drawing for the 3D
part models to send it to the manufacturers.
Catia drafting is of two types
1. Interactive Drafting
2. Generative Drafting
Parts Designed By Using CATIA V5
 Fig 4.6: Designed catia parts

4.7. Assembly Design In CATIA

The Assembly Design used to create an assembly starting from
scratch. Here is illustration of the several stages of creation you may
encounter for an assembly.

4.7.1. Creating An Assembly Document

This task will show you how to enter the Assembly Design workbench
to create a new assembly from scratch. Select the Start -> Mechanical
Design -> Assembly Design command to launch the required workbench.
The Assembly Design workbench is opened. You can see that “Product1” is
displayed in the specification tree, indicating the building block of the
assembly to be created. To create an assembly, you need products. The
application uses the term “product” or “component” to indicate assemblies
or parts. You can use parts to create products. Those products can in turn
be used to create other products. The product document contains: a
specification tree to the left of the application window, specific toolbars to
the right of the application window, a number of contextual commands
available in the specification tree and in the geometry. Note that these
commands can also be accessed from the menu bar.

4.8. Inserting A Components

This task will show you how to insert a component into an existing
assembly. In the specification tree, select Product1 and click the New

Component icon . The structure of your assembly now includes Product1

(Product1.1).

Inserting A New Product

This task will show you how to insert a product in an existing
assembly. In the specification tree, select Product1 and click the New

Product icon. The Product2 (Product2.1) is created in the specification

tree.

Inserting a New Part

This task will show you how to insert a new part in an existing
assembly. In the specification tree, select Product1 and click the New Part

icon . If geometry exists in the assembly, the New Part: Origin Point
dialog box is displayed, proposing two options to locate the part: Click Yes to
locate the part origin point on a selected point, on another component for
example. Click No to define the origin point of a component based on the
origin point of the parent component.

4.9. Defining a Multi-Instantiation

This task shows you how to repeat components as many times as you
wish in the direction of your choice. Select the component you wish to
instantiate. Click the Define Multi-Instantiation icon. The Multi-
Instantiation dialog box is displayed, indicating the name of the component
to be instantiated. The Parameters option lets you choose between the
following categories of parameters to define: Instances & Spacing, Instances
& Length and Spacing & Length. To define the direction of creation, check x-
axis. The application previews the location of the new components. Click OK
to create the components.

4.10. Fast Multi-Instantiation

This task shows you how to repeat components using the parameters
previously set in the Multi Instantiation command. You will use the Fast
Multi-Instantiation command to quickly repeat the component of your
choice. The operation is very simple. Select the component you wish to

instantiate. Click the Fast Multi-Instantiation icon . The result is

immediate. Three components are created according to the parameters
defined in the Multi-Instantiation dialog box.

4.11. Using Assembly Constraints

This section describes the notions and operating modes you will need
to set and use constraints in your assembly structure. Constraints allow
you to position mechanical components correctly in relation to the other
components of the assembly. You just need to specify the type of constraints
you wish to set up between two components, and the system will place the
components exactly the way you want. Setting constraints is rather an easy
task. However, you should keep in mind the following: You can apply
constraints only between the child components of the active component. You
cannot define constraints between two geometric elements belonging to the
same component. You cannot apply a constraint between two components
belonging to the same subassembly if this subassembly is not the active
component. The active component is blue framed (default color) and
underlined. Double-clicking activates it. The selected component is orange
framed (default color).

4.12. Creating A Coincidence Constraint

 Coincidence-type constraints are used to align elements. Depending
on the selected elements, you may obtain concentricity, coaxiality or
coplanarity. Click the Coincidence Constraint icon Select the face to be
constrained. Select the second face to be constrained. Green arrows appear
on the selected faces, indicating orientations. The Constraint Properties
dialog box that appears displays the properties of the constraint. The
components involved and their status are indicated. You can define the
orientation of the faces to be constrained by choosing one of these options:
Undefined (the application finds the best solution), Same, opposite. Click OK
to create the coincidence constraint. This constraint is added to the
specification tree too.

Fig 4.12.constrained properties

4.13. Creating A Contact Constraint

Contact-type constraints can be created between two planar faces

(directed planes). Click the Contact Constraint icon . Select the faces to
be constrained. As the contact constraint is created, one component is
moved so as to adopt its new position. Green graphic symbols are displayed
in the geometry area to indicate that this constraint has been defined. This
constraint is added to the specification tree.

Creating An Offset Constraint

When defining an offset constraint between two components, you need

to specify how faces should be oriented. Click the Offset Constraint icon .
Select the faces to be constrained. The Constraint Properties dialog box that
appears displays the properties of the constraint. The components involved
and their status are indicated. You can define the orientation of the faces to
be constrained by choosing one of these options. Click OK to create the
offset constraint.

Creating An Angle Constraint

Angle-type constraints fall into three categories: Angle, Parallelism
(angle value equals zero), Perpendicularity (angle value equals 90 degrees).
When setting an angle constraint, you will have to define an angle value.

Click the Angle Constraint icon . Select the faces to be constrained. The
Constraint Properties dialog box is displayed with the properties of the
selected constraint and the list of available constraints. Keep the Angle
option. Enter angle in the Angle field and keep Sector 1. Note that four

sectors are available: . Click OK to create the angle constraint.

Fixing A Component
Fixing a component means preventing this component from moving
from its parents during the update operation. There are two ways of fixing a
component: by fixing its position according to the geometrical origin of the
assembly, which means setting an absolute position. This operation is
referred to as “Fix in space”. By fixing its position according to other
components, which means setting a relative position. This operation is
referred to as “Fix”.

Fix In Space:

Click the Fix icon . Select the component to be fixed, that is the
light blue component. The constraint is created. A green anchor is displayed
in the geometry area to indicate that this constraint has been defined.

Fix: Double-click the fix constraint you have just created to edit it. In the
dialog box that appears, click More to expand the dialog box. Uncheck the
Fix in space option to the left of the dialog box. The lock symbol is no longer
displayed in the specification tree, meaning that the component is
positioned according to the other components only. Move the fixed
component. Click OK tocon firm. Update the assembly: now the component
remains at its location.

Fixing Components Together

This task consists in fixing two components together. The Fix Together
command attaches selected elements together. You can select as many
components as you wish, but they must belong to the active component.

Click the Fix Together icon . You can select the components in the
specification tree or in the geometry area. The Fix Together dialog box
appears, displaying the list of selected components. In the Name field, enter
a new name for the group of components you want to create. Click OK. The
components are attached to each other. Moving one of them moves the other
one too.

Using The Quick Constraint Command

The Quick Constraint command creates the first possible constraint

as specified in the priority list. Double-click the Quick Constraint icon .

Select the two entities to be constrained. The possible constrain between
these will be according to list specifying the order of constraint creation:
Surface contact, Coincidence, Offset, Angle and Parallelism. The first
constraint in the list can now be set.

Changing Constraints
Changing a constraint means replacing the type of this constraint by
another type. This operation is possible depending on the supporting
elements. You can select any constraints, not necessarily in the active
component. Select the constraint to be changed. Click the Change
Constraint icon The Change Type dialog box that appears, displays all
possible constraints. Select the new type of constraint. Click Apply to
preview the constraint in the specification tree and the geometry. Click OK

to validate the operation.

Deactivating Or Activating Constraints
Deactivating or activating constraints means specifying if these
constraints must be taken into account during updates or not. Select any
activated constraint. Right-click and select the Deactivate contextual
command. The constraint is deactivated. The graphic symbol representing
the deactivated constraint is now displayed in white. Repeat step and right-
click to select the Activate contextual command to activate the selected
constraint. Updating an assembly means updating its components as well
as its constraints. The application lets you choose between updating the
whole assembly or the components of your choice. The constraints are in
black, indicating they need an update. The default color is black, but the
application allows you to redefine the colors you want. To do so, refer to
Customizing Constraint Appearance. Select the Tools -> Options command,
then expand the Mechanical Design section to the left to access Assembly
Design options. You can choose between two update modes within the
Assembly Design workbench: Automatic or Manual. Check the Manual
option in the Update frame. Click OK to confirm and close the dialog box.

Click the Update icon to update the whole assembly. The assembly is
updated.

Using A Part Design Pattern

This task shows you how to repeat a component using a pattern created in
Part Design. Select the rectangular pattern in the tree or in the geometry.

Control-click to select the component to be . The Instantiation on a

pattern dialog box is displayed, indicating the name of the pattern, the
number of instances to be created (for information only) and the name of the
component to be repeated. There are two work modes: Using associativity
with the geometry: the option “Keep link with the pattern” is on, Using no
associativity: the option is off. To define the first instance of the component
to be duplicated, three options are available: Reuse the original
component, create a new instance, cut & paste the original component.
Click OK to repeat the second component. The new component “xxx on
RectPattern.xx” is displayed in the tree. An entity “Assembly features” has
been created in the tree. “Reused Rectangular Pattern.1” is displayed below
this entity. If you use the option “generated constraints”, the Reuse
Constraints section displays the constraints detected for the component and
makes all original constraints available for selection: You can define whether
you wish to reproduce one or more original constraints when instantiating
the component.

Moving Components
6.8.1 Manipulating Components

Fig 4.13: Moving components

4.14. Snapping Components

The Snap command projects the geometric element of a component onto
another geometric element belonging to the same or to a different
component. Using this command is a convenient way to translate or rotate
components. Depending on the selected elements, you will obtain

First Element Last Element

Result
Selected Selected
Point Point Identical points.
Point Line The point is projected onto the line.
Point Plane The point is projected onto the plane.
Line Line Both lines become collinear.
Line Plane The line is projected onto the plane.
 Plane Line The plane passes through the line.
Table 4.14: Different results

Smart Move
The Smart Move command combines the Manipulate and Snap capabilities.
Optionally, it creates constraints. The Quick Constraint frame contains the
list of the constraints that can be set. This list displays these constraints in
a hierarchical order and can be edited by using both arrows to right of the
dialog box. The application creates the first possible constraint as specified
in the list of constraints having priority.

Sectioning
This task you will create section planes, orient the plane with respect to the
absolute axis system, invert the normal vector of the plane. Click the
Sectioning icon. The section plane is automatically created. The plane is
created parallel to absolute coordinates Y, Z. The center of the plane is
located at the center of the bounding sphere around the products in the
selection you defined. Line segments visualized represent the intersection of
the plane with all products in the selection. The Sectioning Definition dialog
box contains a wide variety of tools letting you position, move and rotate the
section plane. A Preview window, showing the generated section, also
appears. 3D section cuts cut away the material from the plane. Click the
Volume Cut icon in the Sectioning Definition dialog box to obtain a section
cut. You can position section planes with respect to a geometrical target (a
face, edge, reference plane or cylinder axis). You can view the generated
section in a separate viewer.

Assembly Features
Prior to creating assembly features, keep in mind the following. You can
create assembly features only between the child components of the active
product. The active product at least must include two components, which in
turn must contain one part at least. You cannot create assembly features
between two geometric elements belonging to the same component. The
different assembly features you can create are: Split, Hole, Pocket, Remove,
Add, and Perform Symmetry.

Assembly Split
The dialog box that appears when you click Assembly Split, displays the
names as well as the paths of the parts that may be affected by the split
action. Move the parts to the list ‘Affected parts”. Arrows in the geometry
indicate the portion of parts that will be kept after splitting. If the arrows
point in the wrong direction, click them to reverse the direction. Click OK to
confirm. To edit an assembly split, double-click ‘Assembly Split X’ in
assembly features available in history tree.

Creating Scenes
Scenes enable you to: work on the evolution of an assembly in a separate
window from the actual assembly and to impart updates to the assembly as
you see fit. Save a copy of an assembly in a separate window, work on the
evolution of that assembly directly on the assembly. You can modify the
following attributes either in the scene or in the assembly without the
modifications being replicated in the other: the viewpoint, the graphical
attributes of the components, the “show” or “hide” state of the components,
the “active” or “not-active” state of the components. Scenes are identified by
name in the specification tree and by a graphical representation in the
geometry area.

. The Edit Scene dialog box and a scene representation in the document
window are displayed. Click Ok to end the scene creation. You are now in a
scene window: The background color turns to green. Scene 1 is identified in
the specification tree. Perform the required modifications. For instance
modify: viewpoint, graphical attributes, show-no show. Within a scene, click

the Reset selected products icon to reposition the components as they

were in the initial product. Note that color attributes and the show-hide
specification are not taken into account when using the Reset selected
products icon. Click the Exit From Scene icon
 to swap to the initial window. Double-click Scene 1 either in the
specification tree or in the geometry area to swap to the scene window.

4.15. Exploding A Constrained Assembly

This task shows how to explode an assembly taking into account the
assembly constraints. This Explode type is applicable only to specific cases.
When the assembly is assigned coincidence

constraints: axis/axis & plane/plane. Click the Explode icon . The

Explode dialog box is displayed. Wheel Assembly is selected by default, keep
the selection as it is. The Depth parameter lets you choose between a total
(All levels) or partial (First level) exploded view. Keep All levels set by default.
Set the explode type. 3D is the default type. Keep it. Click Apply to perform
the operation.

Detecting Interferences
Checking for interferences is done in two steps: Initial computation: detects
and identifies the different types of interference. Detailed computation:
computes the graphics representation of interferences as well as the
minimum distance. Two interference types are available: Contact + Clash,
Clearance + Contact + Clash. Results differ depending on the interference
type selected for the analysis. Four computation types are
available: Between all components, Inside one selection, Selection
against all, Between two selections. Click Apply to check for interferences.
A progress bar is displayed letting you monitor and, if necessary, interrupt
(Cancel option) the calculation. The Check Clash dialog box expands to
show the results. Clash: red intersection curves identify clashing
products. Contact: yellow triangles identify products in
contact. Clearance: green triangles identify products separated by less than
the specified clearance distance.

Customizing Assembly Design

This task will show you how to customize Assembly Design settings. Select
Tools -> Options. Click the Mechanical Design category, then the Assembly
Design subcategory. The General tab appears, displaying the following
options: Update, Access to geometry, Move components.

Customizing General Settings

Select the Tools -> Options… command. Click the Infrastructure category,
then the Part Infrastructure subcategory. The General tab appears,
containing three categories of options: External References, Update and
Delete Operation
CATIA MODEL OF TROLLEY

Front view Side View

Top view Isometric view

Fig 4.15: Design views in catia
 CHAPTER-5
RAPID PROTOTYPING

5.1. Definition
It is a group of techniques used to quickly fabricate a scale model of a
physical part or assembly using three-dimensional computer aided design
(CAD) data Construction of the part or assembly is usually done using 3D
printing or "additive layer manufacturing" technology.

5.2. History
The first methods for rapid prototyping became available in the late 1980s
and were used to produce models and prototype parts. Today, they are used
for a wide range of applications and are used to manufacture production-
quality parts in relatively small numbers if desired without the typical
unfavorable short-run economics. This economy has encouraged online
service bureaus. Historical surveys of RP technology start with discussions
of simulacra production techniques used by 19th-century sculptors. Some
modern sculptors use the progeny technology to produce exhibitions the
ability to reproduce designs from a dataset has given rise to issues of rights,
as it is now possible to interpolate volumetric data from one-dimensional
images
As with CNC subtractive methods, the computer-aided-design
– computer-aided manufacturing CAD -CAM workflow in the traditional
Rapid Prototyping process starts with the creation of geometric data, either
as a 3D solid using a CAD workstation, or 2D slices using a scanning
device. For Rapid prototyping this data must represent a valid geometric
model; namely, one whose boundary surfaces enclose a finite volume,
contains no holes exposing the interior, and do not fold back on themselves.
In other words, the object must have an "inside". The model is valid if for
each point in 3D space the computer can determine uniquely whether that
point lies inside, on, or outside the boundary surface of the model. CAD
post-processors will approximate the application vendors' internal CAD
geometric forms (e.g., B-spines) with a simplified mathematical form, which
in turn is expressed in a specified data format which is a common feature in
additive manufacturing: STL (stereo lithography) a de facto standard for
transferring solid geometric models to SFF machines. To obtain the
necessary motion control trajectories to drive the actual SFF, rapid
prototyping, 3D printing or additive manufacturing mechanism, the
prepared geometric model is typically sliced into layers, and the slices are
scanned into lines (producing a "2D drawing" used to generate trajectory as
in CNC's tool path), mimicking in reverse the layer-to-layer physical building
process.

5.3. Techniques
• 3D printing (3DP)
• Fused deposition modeling (FDM)
• Laminated object manufacturing (LOM)
• Solid ground curing (SGC)
• Selective laser sintering (SLS)
• Selective laser melting (SLM)
• Stereo lithography

5.4. 3d Printing (3dp)

3D printing is any of various processes in which material is joined or
solidified under computer control to create a three-dimensional object, with
material being added together (such as liquid molecules or powder grains
being fused together), typically layer by layer. In the 1990s, 3D printing
techniques were considered suitable only for the production of functional or
aesthetical prototypes and a more appropriate term was rapid prototyping.
Today, the precision, repeatability and material range have increased to the
point that 3D printing is considered as an industrial production technology,
with the name of additive manufacturing. 3D printed objects can have a very
complex shape or geometry and are always produced starting from a digital
3D model or a CAD file.
There are many different 3D printing processes that can be grouped into
seven categories:
 Vat photo polymerization
 Material jetting
 Binder jetting
 Powder bed fusion
 Material extrusion
 Directed energy deposition
 Sheet lamination
 CHAPTER-6
MATERIALS USED IN PROJECT MAKING

6.1. Tube Less Tires

Dimensions Of Tire
Outer Diameter : 25CM
Inner Diameter : 2.5CM
In some Commonwealth Nations are pneumatic tires that do not require a
separate inner tube.
Unlike pneumatic tires which use a separate inner tube, tubeless tires have
continuous ribs molded integrally into the bead of the tire so that they are
forced by the pressure of the air inside the tire to seal with the flanges of the
metal rim of the wheel
No of tires used are 6
6.2. Ball Bearings
Dimensions bearing: outer diameter is 25mm
Inner diameter is 10mm
A ball bearing is a type of rolling-element bearing that uses balls to maintain
the separation between the bearing races. The purpose of a ball bearing is to
reduce rotational friction and support radial and axial loads. It achieves this
by using at least three races to contain the balls and transmit the loads
through the balls. Ball bearings tend to have lower load capacity for their
size than other kinds of rolling-element bearings due to the smaller contact
area between the balls and races. However, they can tolerate some
misalignment of the inner and outer races
No of bearings used are 12.

6.3. Mild Steel Of L - Angular

Dimensions of 12mm X 12mm.
It is used to making of frame of cart of bottom phase to place goods in trolley
Length of rod is used 9 meters.
6.4. Mild Steel Of Square Rod
Dimensions of 18mmx18mm
Thickness is 5mm
It is used in making of holding frame of cart to hold the goods in trolley to
avoid falling of goods out of boundary
Length of rod used 8 meters.

6.5. Mild Steel Of Hollow Rod

Dimensions of rod diameter is 1inch
Gauge of 5mm
It is used as a shaft of trolley it leads to motion and also it is used as a
handle of trolley
Length of rod is 2 meters.

6.6. Mild Steel Of Flat Rod

Dimension of rod is 10mm meter
It is used as the supports of carts to hold the plywood from base part of cart
Length of rod is used 2 meters.

6.7. Plywood
Dimensions 5feetx3.5 feet
It is used for the base part of holder frame to bear the weights of trolley.

6.8. Cost Estimation Of The Project

S.
Item Description Rate Quantity Price
No.
1 Rubber Wheels OD=250mm 250 each 6 pcs 1500
Deep groove,
2 Ball Bearing 75each 8 pcs 600
SKF6006
3 M.S L-Angular 10mm*10mm 62/kg 19kg 1172

4 M.S. hollow pipe OD=30,ID=26 - 2m long 200

5 M.S Flate Plate 10mm 62/kg 2kg 124

6 M.S. plate square rod 35mmx35mm 70/kg 10kg 700

 50 per
7 Pipe and plate cutting costs 4 Inch plate 4 200
Cut
8 Plasma arc welding - 50 each 2 100

9 Ply wood 750 X 480 mm 30\feet 24 720

Material for Shaft & Bearing
10 - - - 240
housing
11 Washer and Cotter pin - - - 80

12 Welding and Finishing costs - - - 2000

13 Paints(black &blue) - - 75ml 120

TOTAL 7800
 CHAPTER-7
CONCLUSION

Though this project had some limitations regarding the strength and built of
the structure, it can be considered to be a small step forward, as far as Stair
Climbing Vehicles are concerned. During the test run of this project, it was
realized that it wouldn’t be a bad idea to consider this design for carrying
heavy loads up the stairs. This product will be well acclaimed if it can be
commercialized to suit the needs. Though the initial cost of the project
seemed to be higher but more accurate manufacturing would shorten this.

As far the commercial aspects of this product are concerned, if this product
can be fully automated and produced at a lower cost the acceptance will be
unimaginable. Presently, there are no competitors for such a kind of product
in our market.
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