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DESIGN AND DEVELOPMENT OF MULTIUSE TROLLEY

KHAIRUL AZRI BIN NGADIMEN

A report submitted in partial fulfilment of the requirements for the award of the

Diploma of Mechanical Engineering

Faculty of Mechanical Engineering UNIVERSITI MALAYSIA PAHANG

NOVEMBER 2008

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SUPERVISOR’S DECLARATION

We hereby declare that we have checked this project and in our opinion this project is

satisfactory in terms of scope and quality for the award of Diploma in Mechanical

Engineering

Signature

Name of Supervisor: IDRIS BIN MAT SAHAT

Position: TUTOR

Date:

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STUDENT’S DECLARATION

I hereby declare that the work in this thesis is my own except for quotations and

summaries which have been duly acknowledged. The thesis has not been accepted for

any degree and is not concurrently submitted for award of other degree.

Signature

Name: KHAIRUL AZRI BIN NGADIMEN

ID Number: MB06034

Date:

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DEDICATION

First of all, I would like to show my expression of gratitude to Allah s.w.t whose

guidance, help and grace was instrumental in making this humble work a reality. I would

like to express my gratitude to my supervisor Mr Idris Bin Mat Sahat and to the entire

lecturer without whose wise suggestions, helpful guidance and direct assistance, it could

have neither got off the ground nor ever been complete.

I would also like to thank my beloved parents, Ngadimen Bin Arshad and Rosenah

Binti Atan and family, without them, my pursuit of higher education would not have

been possible and I would not have had the change to study for a mechanical course.

Thanks a lot to my university and friends in their support and advice towards this

project. Thanks to all for your enduring patience and continuous encouragement.

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ACKNOWLEDGEMENT

I would like to express my gratitude and appreciation to all those who gave me

the possibility to complete this report. Special thanks is due to my supervisor, Mr. Idris

Bin Mat Sahat whose help, stimulating suggestions and encouragement helped me in all

time of fabrication process and in writing this report. I am very grateful to him for his

patience and his constructive comments that enriched this project.

I would also like to acknowledge with much appreciation the crucial role of the

staff in Mechanical Laboratory, who gave me a permission to use the laboratory

equipment and also the machine and giving a permission to use all the necessary tools in

the laboratory.

Special thanks too go to Mr. Zamri Bin Ahmad, as the Final Year Coordinator,

who has helping a lot and give some advice and share his knowledge on how to

complete this task in the right way.

I also want to thank to all my friends for their support and help to complete the

task and for sharing their knowledge on how to solve the problems. Finally, I thank my

family for their continuous support and confidence in my efforts.

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ABSTRACT

Trolley is the main transport for human to carry load. Every trolley has different

use and specific use. (It’s limited to do other job than the specification). There are some

common problem can be detect at the trolleys nowadays such as don’t have stopper,

load easy to fall (slips surface), heavyweight, only suitable for flat surface road, need

many wheels, hard to cornering, not suitable for small area, cannot load many things,

unstable for heavy duty work, high force needed to push or pull the trolley, hard to

manufacturer and expensive material. To reduce this problem, one new trolley will be

development that have multi function and has not limited to do another task or job.

Nowadays, people use trolley to carry heavy load. There are many type of

trolley in the market like industrial trolley, drum truck trolley and platform truck trolley.

Many trolleys has been developed with a specific task or job like shopping trolley which

can be use only for shopping, bagged trolley is only to carry bags, and transporting tray

trolley only to carry trays. In the fabrication, there are many process involve to develop

the product such as drilling, grinding, joining, measuring, gathering material, cutting

material, and finishing process.

This project is about design and fabricates a new product of trolley that has

multi function. The trolley maximum loads must 200kg, multi use and easy assemble. Its

also must reduce the disadvantages of the trolley in the current market like have

stopper, adjustable and easy manufacturer.

As the conclusion, this project had achieves its entire objective successfully. This

project was done around thirteen week included almost all steps of the report such as

literature review, design, fabrication process and others.

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ABSTRAK

Troli ialah pengangkutan tambahan bagi manusia membawa barang. Setiap troli

ada kegunaan yang tersendiri. Terdapat pelbagai masalah biasa yang boleh didapati pada

troli seperti tidak mempunyai penahan, beban mudah terjatuh, berat, hanya sesuai untuk

jalan yang rata, perlukan banyak tayar, susah untuk membelok, tidak sesuau untuk

kawasan sempit, tidak stabil untuk kerja berat, tidak boleh membawa banyak barang,

perlukan banyak tenaga untuk menolak barang, susah untuk dihasilkan dan bahan

mentah yang mahal. Untuk mengurangkan masalah ini, satu produk baru akan dihasilkan

dan ia mempunyai pelbagai fungsi serta tidak terhad kepada satu kegunaan sahaja.

Pada masa kini manusia menggunakan troli untuk mengangkat beban yang berat.

Terdapat pelbagai jenis troli yang berada dipasaran seperti troli industri, toil membawa

drum, dan troli pelantar. Banyak troli yang telah dihasilkan dengan tugas yang tertentu

seperti troli membeli belah yang hanya digunakan untuk membawa barng sewaktu

membeli belah, dan troli membawa tray hanya sesuai membawa tray. Penghasilan

produk ini melalui pelbagai proses seperti menebuk lubang, proses kisar, menyambung,

mengukur, mengumpul bahan, mengumpul bahan, dan proses mencantikkan produk.

Projek ini bertujuan untuk menghasilkan troli yang mempunyai pelbagai fungsi

dan boleh membawa beban maksimum 200kg dan mudah dipasang. Produk ini juga

mestilah lebih baik daripada produk yang berada dipasaran semasa seperti mempunyai

penahan dan mudah dihasilkan.

Sebagai kesimpulan, projek ini telah mencapai objektif dengan jayanya. Projek

ini telah dijalankan selama tiga belas minggu mengikut langkah-langkah yang terdapat

dalam laporan seperti kajian produk, rekaan, penghasilan dan sebagainya.

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TABLE OF CONTENTS

Page

SUPERVISOR’S DECLARATION ii

STUDENT’S DECLARATION iii

DEDICATION iv

ACKNOWLEDGEMENTS v

ABSTRACT vi

ABSTRAK vii

TABLE OF CONTENTS viii

LIST OF TABLES xi

LIST OF FIGURES xii

CHAPTER 1 INTRODUCTION

1.1 Project Name 1

1.2 Project Synopsis 1

1.3 Project Background 2

1.4 Problem Statement 2

1.5 Project Objective 3

1.5.1 General Objective 3

1.5.2 Specific Objective 3

1.6 Project Scope 4

1.7 Project Gantt Chart 5

1.8 Flow Chart 6

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction 7

2.2 Technical Review 8

2.2.1 Product A 8

2.2.2 Product B 9 2.2.3 Product C 10

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2.2.4 Product D 11

CHAPTER 3 METHDOLOGY

3.1 Project Flow Chart 12

3.2 Design 15

3.3 Drawing 15

3.4 Sketching And Drawing Selection 16

3.41 Concept A 17 3.42 Concept B 17 3.43 Concept C 18

3.5 Concept Generation And Evaluation 19

3.6 Computer Aided Design Drawing 20

3.7 Analysis of Design 21

3.7.1 First Design 21

3.7.2 Second Design 21

3.8 Result of Failure Analysis 22 3.8.1 Result of Failure for First Analysis 22

3.8.2 Result of Failure for Second Analysis 22

3.9 Bill of Material 23

3.10 Fabrication Process 24

3.10.1 Process Involved 24

3.10.2 Gathering Material 25

3.10.3 Measuring 25

3.10.4 Cutting Material 25

3.10.5 Joining Process 26

3.10.6 Grinding Process 26

3.10.7 Drilling Process 27

3.10.7 Finishing Process 27

CHAPTER 4 TESTING, RESULT AND DISCUSSION

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4.1 Final Product 28

4.1.1 Result after Finishing 28

4.2 Testing 29

4.2.1 Test 1(Maximum load of 200kg) 29

4.2.2 Test 2(Functional Trolley with Extra Feature) 30

4.3 Result and Analysis 31

4.4 Product Specification 31

4.5 Discussion 32

4.5.1 Type of Defect 32

4.5.1.1 Gap 33

4.5.1.2 Bead 33

4.5.2 Problem in Progress 34

4.5.2.1 Literature Review Problem 34

4.5.2.2 Fabrication Problem 34

4.6 Safety 35

4.6.1 Rubber Lid 35

CHAPTER 5 CONCLUSION AND RECOMMENDATIONS

5.1 Introduction 36

5.2 Conclusion 36

5.3 Recommendation 37

5.4 Future Work 37

REFERENCES 38

APPENDICES 39

A Solid Work 2D Drawing (body part) 39

B Solid Work 2D Drawing (Explode view) 40

C Final Product (Full View) 41

D Final Product (Explode View) 42

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LIST OF TABLES

Table No. Page 3.1 Table of Pugh concept 19 3.2 Bill of material 23 4.1 Product specification 32

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LIST OF FIGURES

Figure No. Page 2.1 Product A 8 2.2 Product B 9 2.3 Product C 10 2.4 Product D 11 3.1 Flow chart 14 3.2 Concept A 16 3.3 Concept B 17 3.4 Concept C 17 3.5 Concept D 18 3.6 Solid work picture 20 3.7 Analysis force at the side 21 3.8 Analysis force at the center 21 3.9 Result for first analysis 22 3.10 Result for second analysis 22 3.11 Type of material 25 3.12 Measuring dimension 25 3.13 Cutting material 25 3.14 Joinning process 26 3.15 Grinding process 26 3.16 Drilling process 27 3.17 Finishing process 27

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4.1 Complete view 28 4.2 Complete view (explode view) 29 4.3 Testing of the maximum load 30 4.4 Testing of the maximum load 30 4.5 Testing of multiuse 31 4.6 Testing of multiuse 31 4.7 Testing of multiuse 31 4.8 Product gap 33 4.9 Bead 34 4.10 Rubber lid 36

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CHAPTER 1

INTRODUCTION

1.1 PROJECT NAME

The title for this project is Multi Use Trolley. Trolleys design must have multi

function use and strength.

1.2 PROJECT SYNOPSIS

Nowadays, trolley has become an important thing to humans. Trolley is use to

carry heavy things and others. One new product will be developed base on the product

in the market and it can compete again other product in the world wide market and also

base on my study in ump.

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1.3 PROJECT BACKGROUND

Nowadays, trolley becomes the common facilities for human. There are many

type of trolley in the world wide market like airport trolley, bagged trolley, shopper

trolley, industrial trolley and others. The main purpose of the trolley invention is to

replace human force to do heavy duty work. Its can reduce cost for the work, time of

work and efficiency.

As the result for the needed in community there are various type of portable or

multi use trolley had been invented. Trolley has a multi function that can be use and to

carry various type of load, easy storage and use in small and big area. It also comes in

much type of size and design. From the advantages and disadvantages of the trolley in

the current market, one new product will be developed to follow the specific and

customer need.

1.4 PROBLEM STATEMENT

Trolley is the main transport for human to carry load. There are many type of

trolley like cylinder trolley, shopping trolley and tray trolley. Every trolley has different

use and specific use. It’s limited to do other job than the specification). There are some

common problem can be detect at the trolleys nowadays such as don’t have stopper,

load easy to fall (slips surface), heavyweight, only suitable for flat surface road, need

many wheels, hard to cornering, not suitable for small area, cannot load many things,

unstable for heavy duty work, high force needed to push or pull the trolley, hard to

manufacturer and expensive material. To reduce this problem, one new trolley will be

development that have multi function and has not limited to do another task or job.

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1.5 PROJECT OBJECTIVE

Project objective is dividing into two objectives. First is general objective and

second is the specific objective for the project.

1.5.1 General Objective

Diploma final year project is to practice the knowledge and skill of the student

that have been gathered before in solving problem using academic research to born an

engineer that have enough knowledge and skill.

1.5.2 Specific Objective

The specific objectives for this project are:

(i) To design a trolley that has a lot of function.

(ii) To fabricate a functional trolley with extra features.

(iii) Can be loaded maximum 200kg.

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1.6 PROJECT SCOPE

This project is about design and fabricates a new product of trolley that has

multi function. The trolley maximum loads must 200kg, multi use and easy assemble. Its

also must reduce the disadvantages of the trolley in the current market like have

stopper, adjustable and easy manufacturer.

(i) To apply all related subject like industrial design, static and dynamic in the product

design and strength analysis (failure analysis).

(ii) Conceptualization is to concentrate creating the product form using simple sketch.

(iii) Final concept selection is to draw in 2D or 3D often used for color studies and for

testing the products feature and functionality.

(iv) Trolley must have multi use.

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1.7 PROJECT GANTT CHART

WEEK TASK

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Literature review

Research on existing product

Brainstorming and idea development

Concept selection and detail design

Analysis of design, cost and failure

Fabrication

Discussion and findings

Report Writing

Presentation project

= Planning progress

= Actual planning

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START

Literature Review

Research Existing Product

Concept Selection

Brainstorming and Idea Development

Design on concept (Sketch)

Analysis of Design (Cost and Failure)

Detail Design

Fabrication

Prototype

Product

NO YES

NO

YES

1.8 FLOW CHART

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CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

Nowadays, people use trolley to carry heavy load. There are many type of

trolley in the market like industrial trolley, drum truck trolley and platform truck trolley.

Many trolleys has been developed with a specific task or job like shopping trolley which

can be use only for shopping, bagged trolley is only to carry bags, and transporting tray

trolley only to carry trays.

The purpose of this chapter is, from the existing product, function of a new

product of trolley can be developed according to the needed in the society. These new

trolley are being developed based on the advantages and disadvantages of the existing

product in the current market. The new product of trolley also will be developed

according to the objective of the project which is can be loaded maximum 200kg and

have multiuse.

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2.2 TECHNICAL REVIEW 2.2.1 Product A

Figure 2.1: Product A

All welded construction (except casters and removable handle). Durable 12

gauge steel platform, and 12 gauge caster mounts.1 1/4" tubular handle with smooth

radius bend. Bolt on casters, 2 swivel & 2 rigid, for easy replacement and superior cart

tracking.1-1/2" platform lips down for flush load and unload. Handle height above deck

- 30". Advantages of this product are built for durability and mobility of heavy loads,

easy to maintenance, versatility, and ideal for transporting heavy load in industrial.

Disadvantages of this product are don’t have stopper, load easy to fall (slips surface),

heavyweight, and only suitable for flat surface road.

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2.2.2 Product B

Figure 2.2: Product B

Durable 12 gauge steel platform and 12 gauge caster mounts for long lasting

use. Two removable 1 1/4" tubular handles with smooth radius bend. Bolt on casters, 4

(5" x 2") swivels on ends & 2 (5" x 2") rigid centers mounted, for easy replacement and

superior cart tracking. Tilt feature uses larger center casters for center pivoting.1-1/2"

platform lips down for flush load and unload Platform height - 9".Handle height above

deck - 48". Advantages of this product are extra heavy duty, load many things,

flexibility, and twin handle. Disadvantages of this product are needed many wheels, hard

to cornering, not suitable for small area, not suitable to carry small things like helmet,

book, shoes, and stuff easy to fall (slips surface).

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2.2.3 Product C

Figure 2.3: Product C

This trolley can be used as a hand truck or drum truck. Chime hook works with

55-and 30- gallon drums. The trolley have curved frame accommodates 5-gallon pails

and kegs.15" depth. With nose plate resting flat on floor, 18” to center of lowered

chime hook. Advantages of this trolley are lightweight, easy removal, easy to

manufacturer, and easy to maintenance. Disadvantages of this trolley are cannot load

many things, unstable for heavy duty work, high force needed to push or pull the trolley,

and not suitable for industrial use.

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2.2.4 Product D

Figure 2.4: Product D

“U" shaped handle and frame design for added strength and durability. This

trolley is ideal for transporting trays and other supplies. Platform is 10 1/4" (260) from

floor. Convenient dual handle maneuvering. Cleans and sanitizes easily. Advantages of

this trolley are heavy duty, easy to operate, clean body and surface (attractive), and

versatility. Disadvantages of this trolley are heavy weight, ideal only for transporting

trays, don’t have stopper, hard to manufacturer, and expensive material.