Design of a modified sensor controlled convertible cart-trolley
Group 4
02 November 2020
Group Members
Mafanya K Nkomo S Ngomane BR
Siyaya SG (Group Leader)
218051398 218045715 217010066
218090614
Makane M Hendricks ZC Masinde OM Mogale N
218069320 218041122 216006679 218010732
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Project Background
Problem Statement
In developing countries, handling and transportation of material and goods in short distance are done manually which is a
time consuming and laborious process, to overcome this challenge a cheap sensor controlled convertible cart-trolley needs
to be designed.
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Flow Chart of Design Project
Review Existing
Concepts
Formulate a Decision
Research Literature Matrix
Concept Selection
Planned Concept Generation
Define and Technical
Project Flow Understand Specifications Material Selection
Chart the Problem (Calculations etc.)
Preliminary Design
Concept
Brainstorm Ideas
Final Design Concept
Individual Part Drawings Assembly
Final Report and
First Report Draft
Presentation
Specifications and Constraints
Unit weight 20 - 30 kg
Large load capacity 200 - 300 kg platform
120-160 kg 2-wheel
Wheels 25.4 cm max Pneumatic
Castors 12.7 cm max solid rubber
Maintenance Low maintenance
Delivery power Less or equal to 40 hp
Steady state input speed 1000 r.p.m.
Steady state output speed 90 - 100 r.p.m.
Long travel mileage 10 km
Battery 12 V (2,5 kg)
1000 charging cycles
Safe, light, reliable
Pollution free
Easily chargeable
Easily changed
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Existing Convertible Cart-Trolleys
Magliner Gemini 6-Wheel Stair Magliner 2-Wheel
Convertible 3-in-1 Climber Hand Motorized Hand Magliner Folding
Hand Truck Truck Truck Truck
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Conceptual Convertible Cart-Trolleys Designs
Foldable 3 Position Sliding Bulk Convertible Motor Powered
Mechanism Convertible Convertible Hand Hand Truck Convertible Hand
Convertible Cart Electric Trolley Trolley Trolley
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Scoring Matrix
Reference Concept:
Three Position Motor-Powered
2-in-1 Milwaukee Foldable Mechanism Sliding Convertible Bulk Convertible
Electric Convertible Convertible Hand
Convertible Hand Convertible Cart Hand Trolley Hand Truck
Trolley Trolley
Truck
Criteria Importance
1 Lightweight 4 1 0 1 -2 2
2 Safety 5 1 1 1 1 2
3 Portable 4 2 2 2 -1 2
4 Manufacturability 5 1 1 0 0 -1
5 Convertibility 5 0 2 2 1 2
6 Ease of Assembly 3 0 -1 0 1 0
DATUM
7 Ease of operation 4 1 2 2 1 2
8 Storage Capabilities 1 0 1 1 0 2
9 Loading Capacity 4 -2 1 0 2 1
10 Ease of Repair 4 1 -2 -2 1 -1
Total 11 13.5 12.5 11 19
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Preliminary CAD Drawing
From the final preliminary rough sketch, we generated our cad drawing. This excluded sensor controlled
electronics and mechanical fasteners.
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Final CAD Drawing
With perseverance we finally, reached our final design. After evaluation of the preliminary design, it was observed that the
design was too conventional, thus we modified and improved the design.
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Features of Final Sensor-Controlled Convertible Cart-Trolley
Ergonomic
Modern 90⁰ Handle
Lightweight with Control
Frame with Instrument
portable (Power Switch,
capabilities Emergency
Toggle etc.)
Dual Electronic Box
Brushless with Ardiuno
DC Motors Board,
Removable,
Portable
Charging
Battery Case
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Versatility 3-in-1 Convertible
Cart Position Incline Position Trolley Position
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Material Selection
• The frame material and the structure affect the weight of the trolley, durability, its resistance to corrosion,
vibration, the type and the strength of castor mounting. For the fabrication of the frame of the cart powder
coated mild steel circular shaped tubes will be used.
• For the fabrication of the shelf of the cart, sheet steel will be used.
• Wheels of the cart - Caster combination: Two rigid (front wheels), one swivel (rear wheel). This configuration is
the most practical and cost-effective.
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Software analysis
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Calculations
Case 1 Calculations.
The number of motors: 2
Mass (mass of trolley plus mass of all maximum load): 300 kg
Maximum incline: 20
Radius of drive wheel: 260 mm
Velocity: 0.5 m/s or 30 m/min or 1800 m/hr or 1.8 km/hr
Supply voltage: 12 V
Acceleration: 0.2 m/s
Operating time: 15 min
Total efficiency: 50
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Case 2 calculations
The number of motors: 2
Mass (mass of trolley plus mass of all maximum load): 300 kg
Radius of drive wheel: 260 mm
Velocity: 2 m/s or 120 m/min or 7200 m/hr
Supply voltage: 12 V
Acceleration: 0.2 m/s
Operating time: 60 min
Total efficiency: 50
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From the calculations above it can be seen that a 20Ahr battery,
120W power motor, and a motor controller that can handle 10A
electricity are to be used in this project.
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Components of Circuit of the Arduino human following robot
Infrared Obstacle Avoidance
Toggle Switch
Arduino Mega 2560 R3 With USB Cable Sensor
autonomous circuit board layout
Battery Capacity Tester with LCD Rechargeable battery Ultrasonic Sensor Ranging Module Micro Servo
Motor Driver Shield L293D Module
Indicator for 12V Lead acid Lithium LiPo PH2.0 Interface Electronic Building
Duemilanove Mega UNO
Blocks
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Brushed DC Geared motor
Crouzet ,12 V Brushed DC Motor
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Bills of Material
Parts Specification Length Unit Unit Price Total Price Shop Contact Person Contact Details
Mild Steel Flat Sheet Galv.1850×925×0.4mm 3m 1 R173,65 R199.70 Rocha’s Paint and Building supplies Felix 0116241004/9
Steel Sheet Hot Rolled 1.6mm×2450mm×1225mm 3m 1 R695.49 R799.81 Rocha’s Paint and Building supplies Felix 0116241004/9
Mild Steel Flat Bar 50mm×5mm×6.0m 6m 0.5 R243.43 R139.97 Rocha’s Paint and Building supplies Felix 0116241004/9
Tubing Round RT2016 20×1.6mm×6m 6m 0.5 R100.83 R57.98 Rocha’s Paint and Building supplies Felix 0116241004/9
Tubing Round RT3216 32×1.6mm×6m 6m 0.5 R167.50 R96.31 Rocha’s Paint and Building supplies Felix 0116241004/9
Round Mild steel MR16 16mm×6m 6m 0.5 R180.66 R103.88 Rocha’s Paint and Building supplies Felix 0116241004/9
Motor Servo Motor Servo 180-DEG 5V Micro Analog _ 1 R38.30 R38.30 MANTECH SHARON B 0114939307
Toggle Switch Toggle switch DPDT ON-OFF _ 1 R34,80 R34,80 MANTECH SHARON B 0114939307
ULTRASONIC REFLECTIVE HC-SR04 _ 1 R43.46 R43,46 MANTECH SHARON B 0114939307
SENSOR
ARDUINO ARDUINO MEGA260 R3 IMPROVED W/CABLE _ 1 R294.94 R294.94 MANTECH SHARON B 0114939307
EASY-PLUG IR OBSTRACTLE EASY-PLUG IR OBSTRACTLE AVOIDANCE SENSOR _ 2 R60,74 R121.48 MANTECH SHARON B 0114939307
AVOIDANCE SENSOR
JUMPER LEADS JUMPER LEADS 200mm 40W PLUG-SOCKET M/C _ 1 R20.78 R20.78 MENTECH SHARON B 0114939307
Battery 12V BAT SLA 12V 20AH 181×77×167 TERM-MS _ 1 R596.69 R596.69 MENTECH SHARON B 0114939307
BALL BEARING MH-PN260B25-260MM BALL BEARING _ 2 R245,00 R563.50 IAN BROWN ENGINEERING 0117081929
SWIVEL BRAKED CASTOR MH-EM01.100F SWIVEL BRAKED CASTOR 104×80 _ 1 R125.00 R143.00 IAN BROWN ENGINEERING 0117081929
Dual-Channel H Bridge Motor 50A Module For Arduino Robot Chassis Servo - 1 R550 R550
Driver
Brushed DC Geared Motor 12 V dc, 200 Ncm, Brushed DC Geared Motor, Output Speed 40 - 2 R2355.55 R4711.10 RS-Online 0860007772
rpm
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TOTAL R8515.68
Project Planning
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Conclusion
• From the work done, a lot of refinements were made to improve the functionality, performance and efficiency of the cart
trolley system. The electronic system of the trolley requires programming, this was advantageous to the group as all
members were able to Acquire the basics of programming knowledge and skills which might aid at the workplace.
• The project design of a modified sensor controlled convertible cart-trolley was a success as all parameters of the design
where utilized and we were able to come out finally with our final design of the project.
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Thank You
