Design and development of multi axis trolley

1. INTRODUCTION:

Automation can be achieved through computers, hydraulics, hydraulics, robotics, etc., of these
sources, hydraulics form an attractive medium. Automation plays an important role in
automobile. Nowadays almost all the automobile vehicle is being atomized in order to product the
human being. The automobile vehicle is being atomized for the following reasons:

 To achieve high safety

 To reduce man power
 To increase the efficiency of the vehicle

 To reduce the work load

 To reduce the fatigue of workers
 To high responsibility
 Less Maintenance cost

1.1 SELECTION OF PNUMATIC SYSTEM

If less force and higher speed is required, then pneumatic system Should be selected.

As air is compressible in nature, it can not be pressurized to large amount of pressure. Since the
pressure of compressed air is less (about 10 bar), force developed is also less.
Pneumatic system are faster in operation because, air is very less viscosity. it can flow very
quickly. Air rushes into the cylinder once the valve is opened and within no time, the cylinder
extends.

1.2 ADVANTAGES OF PNUMATICS OVER HYDRAULICS

 The air used in pneumatic devices is dried and free from moisture so that it does not
create any problem to the internal parts of the system
 Moreover, to avoid corrosive actions, oil or lubricants are added so that friction effects
can be reduced. Compressed air is used in most of the machines and in some cases
compressed carbon dioxide is used.

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 As most of the pneumatic devices are air based, they have a less complicated design and
can be made of inexpensive material.
 Mass production techniques can be adopted to produce pneumatic systems, which not
only save money but save time too
 Initial cost is less; hydraulics equipment cost as much as twice the price of pneumatic
equipments.

1.3 METHODOLOGY

Fig.1.3.1 Line Diagram For Three Axis Pneumatic Trolley

In this project we are using single cylinder instead of three as per used in current
dumping trolley. In this we are mounting a pneumatic cylinder on rotating plate which will
rotate along with axis.
The project mechanism has mainly concentrated on the difficulty of loading and hence a
suitable arrangement has been designed. Such that the load can be unloaded from the trolley in
three axis without application of any impact force. By pressing the direction control valve
activated. The compressed air is goes to the pneumatic cylinder through valve. The ram of the
pneumatic cylinder acts as a lifting the trolley cabin. The automobile engine drive is coupled to
the compressor engine. So that it stores the compressed air when the vehicle running. This
compressed air is used to active the pneumatic cylinder. When the valve is activated.
Pneumatic three axis trolley is nothing but one of the lifting system in automobile at the
time of emergency. in this lifting system pneumatically operated one. Here the additional

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pneumatic cylinder and control valve is provided in the automobile it self. In this project, the
control vale is used to activate/deactivate the air input.
The valve is ON at the time of emergency; the compressed air goes to the pneumatic
cylinder. Then the compressed air passes through the tube, and then pushes the pneumatic
cylinder, so that the lifting is applied at the time of valve is ON position. The speed of the
pneumatic cylinder is varied by using flow control valve. This is the way of controlling lifting
speed of the trolley at the time of emergency.
In our project we have to apply pneumatic trolley mechanism in load lifting vehicles.
The control valve is fixed in near of the driving persons in the four wheels. the air tank
contains the compressed air already filled. The valve was ON at the time of emergency, the
control valves was activated. The compressed air is flow is controlled by the valve. Then the
compressed air goes to the pneumatic cylinders. The pneumatic cylinders piston moves
forward at the time of compressed air inlet to the cylinder.

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2. LITERATURE REVIEW

[1] S. N. Waghmare et al stated that during the study of the conventional system the dumpers that
are used are not that much active and there lacking of the new inventions and the technology. The
study in taken into consideration of several automobile workshops, it shows the fact that most of
the difficult method was been adopted in the areas of the unloading of the material. This paper has
mainly concentrated on above difficulty. Hence a prototype of such suitable arrangement has
designed. The vehicle can be unloaded from the entire three direction of the mechanism can be
control with the help of providing sideways to the mechanism.. This mechanism will prevent road
blocking.

[2] Prof. R.S. Ambade et al stated that This project work titled “UNIVERSAL MODERN
TRAILER” has been found again difficulties in unloading of the material. Revealed the facts so
mostly some difficult types of methods were adopted in unloading the materials from the trailer.
The trailer will unload the material in only one single way axes. It is difficult to unload the
materials in small compact area or site and small roads. In our project these are overcome to unload
the trailer in all of the sides very easily. Conventional dumper vehicle unload materials only in
single direction that to only at the rear side of the tipper by using various powerful pneumatically
cylinders, which may cause the problems of blockage when the work area is limited.

[3] The Multidirectional dumper is the solution of this problem. Unloading the material by using
mechanical arrangement one side. By using gear and linkage attachment material can be unloaded
in 180degree requirement. The all directional dumper is developed and tested for its movement in
all 180 possible angles to unload the materials in the tipper trolley and monitor the inclinations for
its gradualism (linearity).Now a day’s hydraulic and pneumatic system is generally use in trolley
for unloading purpose but our aim is to check performance of mechanical system.

[4] Mr. Abhimanyu D. Deshmukh et al stated that The earlier techniques followed the difficulties in
removing sand and assets. there are many survey in the regards in automobile garages, revealed the

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facts wich are mostly difficult methods were adopted in unloading the materials from the trailer or
dumper . This paper has mainly focused on above problem. So as to find the solution the
protypewas designed.Vehicles can be unloaded from the trailer in three axes without applying any
kind of foreign force. There are way of the mechanism are be control with the help of ball and
socket joint which connected to ram of the hydraulic cylinder which lifting the dumper cabin in
require side. Further modifications and working limitations which will put this work in the main
league of use. This research paper is help to saves time & energy which helpful and efficient .

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3. COMPONENTS AND DESCRIPTION

SINGLE ACTING PNEUMATIC CYLINDER

Fig. 3.1 Single acting cylinder

These cylinders produce work in one direction of motion hence they are named as single acting
cylinders. Figure 6.4.1 shows the construction of a single acting cylinder. The compressed air
pushes the piston located in the cylindrical barrel causing the desired motion. The return stroke
takes place by the action of a spring. Generally the spring is provided on the rod side of the
cylinder.

A single-acting pneumatic cylinder is a type of pneumatic actuator that uses compressed air to
create linear motion in one direction. Unlike double-acting cylinders, which use air pressure to
move the piston in both directions, single-acting cylinders rely on a spring or other external
force to return the piston to its original position.

Key Features:
One Directional Movement: Single-acting cylinders provide force and motion in one direction
only, typically extending the piston rod when air pressure is applied and retracting it when the
pressure is released.

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Spring Return: The piston is usually equipped with a spring that returns it to the starting
position when the air pressure is released. This spring provides the force needed for the piston
to retract.
Simple Design: Single-acting cylinders have a simpler design compared to double-acting
cylinders, as they do not require seals or mechanisms for controlling movement in both
directions.

Cost-Effective: Due to their simpler design, single-acting cylinders are often more cost-
effective than double-acting cylinders, making them suitable for applications where cost is a
factor.

Applications:
Single-acting cylinders are commonly used in applications where a return stroke is not
required, such as clamping, lifting, and pushing applications.

Advantages:
Cost-Effective: Single-acting cylinders are typically less expensive than double-acting
cylinders.

Simple Design:
The simple design of single-acting cylinders makes them easy to install and maintain.
Energy Efficiency: Single-acting cylinders require air pressure only for the extension
stroke, making them more energy-efficient in certain applications.
Reliability: Single-acting cylinders are known for their reliability and long service life.
Disadvantages:
Limited Motion: Single-acting cylinders can only provide linear motion in one direction,
limiting their use in applications requiring bi-directional movement.
Spring Fatigue: The spring in a single-acting cylinder may wear out over time, requiring
replacement.
Less Control: Single-acting cylinders offer less control over the speed and force of the

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piston compared to double-acting cylinders.
In summary, single-acting pneumatic cylinders are a cost-effective and reliable option for
applications requiring linear motion in one direction. They are commonly used in various
industries for tasks such as clamping, lifting, and pushing.

Piston compressors are commonly used in pneumatic systems. The simplest form is single
cylinder compressor. It produces one pulse of air per piston stroke. As the piston moves down
during the inlet stroke the inlet valve opens and air is drawn into the cylinder. As the piston
moves up the inlet valve closes and the exhaust valve opens which allows the air to be expelled.
The valves are spring loaded. The single cylinder compressor gives significant amount of
pressure pulses at the outlet port. The pressure developed is about 3-40 bar.

FLOW CONTROL VALVE

Fig 3.3 flow control valve 5/2

A flow control valve is a type of valve used to regulate the flow rate of a fluid in a hydraulic or
pneumatic system. It is designed to control the speed and direction of a fluid as it moves
through the system, allowing for precise control over the movement of actuators, cylinders, and
other components. Flow control valves come in various types and configurations, each suited
for different applications and operating conditions.

Key Features:

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Flow Rate Adjustment: Flow control valves allow for the adjustment of the flow rate of a
fluid, either manually or automatically, to control the speed of an actuator or cylinder.
Directional Control: Some flow control valves can also control the direction of flow, allowing
for bi-directional control of hydraulic or pneumatic systems.
Pressure Compensation: Many flow control valves are designed to compensate for changes in
pressure, ensuring a consistent flow rate regardless of variations in system pressure.

Types: Flow control valves can be categorized into different types based on their design and
operation, including needle valves, throttle valves, and spool valves, among others.

Applications:
Hydraulic Systems: Flow control valves are commonly used in hydraulic systems to control
the speed of hydraulic actuators, such as cylinders and motors.
Pneumatic Systems: In pneumatic systems, flow control valves are used to regulate the speed
of pneumatic actuators, such as cylinders and air motors.
Process Control: Flow control valves are also used in various process control applications,
such as in chemical processing, water treatment, and oil refining, to regulate the flow of fluids
in pipes and pipelines.

Advantages:
Precise Control: Flow control valves provide precise control over the flow rate of a fluid,
allowing for accurate control of the speed and direction of actuators.
Energy Efficiency: By controlling the flow rate, flow control valves can help optimize the
energy efficiency of hydraulic and pneumatic systems.
System Protection: Flow control valves can help protect hydraulic and pneumatic systems
from damage due to excessive flow rates or pressure.

Disadvantages:
Complexity: Flow control valves can add complexity to hydraulic and pneumatic systems,
requiring careful design and installation.
Maintenance: Like any mechanical component, flow control valves require regular

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maintenance to ensure proper operation and prevent failures.
Cost: Flow control valves can be more expensive than simple on/off valves, especially for
high-performance or specialized applications.
In summary, flow control valves are essential components in hydraulic and pneumatic systems,
providing precise control over the flow rate of fluids and enabling the efficient operation of
actuators and other components.

GEARED DC MOTOR

Fig. 12 V DC Geared Motor

A geared 12V DC motor is a type of electric motor that is designed to operate on a 12-volt direct
current (DC) power supply and is equipped with a gearbox (or gear train) to provide the motor
with increased torque and lower speed. These motors are commonly used in a variety of
applications where a combination of high torque and low speed is required, such as in robotics,
automotive mechanisms, and industrial equipment.
Here are some key features and characteristics of geared 12V DC motors:

Voltage: These motors are designed to operate on a 12V DC power supply, which is common in
many applications and can be easily provided by batteries or power supplies.

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Gearbox: The gearbox is an integral part of the motor and is used to reduce the speed of the
motor while increasing its torque output. The gearbox consists of a series of gears that transmit
power from the motor to the output shaft, providing the desired speed and torque characteristics.

Torque: Geared DC motors are known for their high torque output, which makes them suitable
for applications where high starting torque or lifting force is required.

Speed: The speed of a geared DC motor is inversely proportional to the gear ratio of the gearbox.
By selecting the appropriate gear ratio, the motor's speed can be adjusted to suit the requirements
of the application.

Efficiency: Geared DC motors are generally efficient in converting electrical energy into
mechanical energy, although efficiency can vary depending on the design and quality of the
motor.

Size and Weight: Geared DC motors can vary in size and weight depending on their power rating
and torque output. Smaller motors are typically used in lighter applications, while larger motors
are used in heavier-duty applications.

Overall, geared 12V DC motors are versatile and reliable components that are widely used in
various industries due to their high torque output, low speed operation, and compatibility with 12V
power supplies.

BATTERY

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Fig 3.5 12 v dc battery
A dc motor is simple working device which converts electrical energy into mechanical energy. Dc
motor is provide the rotary motion of the trolley. Her 12 v dc , 15 rpm rotate the gear.

GEAR
A 3D printed yellow-colored gear pair refers to a set of gears that have been manufactured using
3D printing technology and are colored yellow. Gears are mechanical devices with toothed
wheels that mesh with each other to transmit torque and motion. 3D printing, also known as
additive manufacturing, is a process of creating three-dimensional objects by adding material
layer by layer based on a digital model.

Fig. Gear

A gear is a rotating machine part having cut teeth , or cogs, which mesh with another toothed
part to transmit torque. Geared devices can change the speed, torque, and direction of a power
source. Gears almost always produce a change in torque, creating a mechanical advantage,
through their gear ratio, and thus may be considered
a simple machine. The teeth on the two meshing gears all have the same shape. Two or more
meshing gears, working in a sequence, are called a gear train or a transmission. A gear can
mesh with a linear toothed part, called a rack, producing translation instead of rotation.

Key Features:
Material: The gears are made from a 3D printable material, such as PLA (polylactic acid) or ABS
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(acrylonitrile butadiene styrene), which are commonly used for their strength and durability.
Color: The gears are colored yellow, which can be achieved by using a yellow filament or by
post-processing techniques such as painting or dyeing.
Design: The gears are designed with specific tooth profiles and dimensions to ensure smooth and
efficient meshing.
Advantages of 3D Printed Gears:
Customization: 3D printing allows for the customization of gear designs to suit specific
applications, such as adjusting the tooth profile or size.
Rapid Prototyping: 3D printing enables quick and cost-effective prototyping of gear designs
before mass production.
Complex Geometries: 3D printing can produce gears with complex geometries that are
difficult or impossible to achieve with traditional manufacturing methods.
Low Cost: For low-volume production, 3D printing can be a cost-effective option compared to
traditional machining methods.

Applications:
Prototyping: 3D printed gears are commonly used in the prototyping stage of product
development to test and validate gear designs.
Custom Machinery: They are used in custom machinery and equipment where off-the-shelf
gears are not suitable.
Educational Purposes: 3D printed gears are used in educational settings to demonstrate gear
principles and mechanisms.
Hobbyist Projects: They are popular in hobbyist projects such as robotics, model making, and
mechanical toys.

Limitations:
Strength: While 3D printed gears can be strong, they may not be as durable as gears made
from traditional materials such as metal.
Surface Finish: The surface finish of 3D printed gears may not be as smooth as gears produced
by traditional machining methods.

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Material Properties:
The material properties of 3D printed gears, such as temperature resistance and wear resistance,
may be inferior to traditional materials.
In summary, 3D printed yellow-colored gear pairs are versatile components that offer
customization and rapid prototyping capabilities, making them suitable for a wide range of
applications in various industries.

WHEEL ARRANGEMENT
A caster (also castor according to some dictionaries) is a wheeled device typically mounted to a
larger object thatenables relatively easy rolling movement of the object. Casters are essentially
special housings that include a wheel, facilitating the installation of wheels on objects. Casters are
found virtually everywhere, from office desk chairs to shipyards, from hospital beds to
automotive factories.. They range in size from the very small furniture casters to massive
industrial casters

Fig 3.8 Wheel

FORWARD AND REVERSE SWITCH

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Fig. rocker R/F Switch

A rocker DPDT (Double Pole Double Throw) switch is a type of electrical switch that is
commonly used in circuits where two separate circuits need to be controlled simultaneously.
The switch has a rocker mechanism that allows it to be toggled between two positions, each of
which can control a different circuit. Here's a breakdown of its key features and applications:

Key Features:
Poles: DPDT switches have two sets of contacts (poles) that can be used to control two separate
circuits.
Throws: Each pole has two possible positions (throws), typically labeled as "on" and "off."
Actuation: The switch is actuated by pressing one side of the rocker, which toggles it to the
opposite position.
Mechanism: The rocker mechanism provides a smooth and easy-to-operate switching action.
Terminal Types: DPDT switches can have a variety of terminal types, including solder
terminals, screw terminals, and quick-connect terminals.
Applications:
Electronics: Used in electronic devices and appliances to control power and functions.
Automotive: Used in automotive applications to control lights, fans, and other accessories.
Industrial: Used in industrial equipment and machinery for control and safety functions.
Electrical Panels: Used in electrical panels for controlling circuits and equipment.

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DIY Projects: Suitable for various DIY projects requiring a reliable switching mechanism.

Advantages:
Versatility: DPDT switches can control two separate circuits, providing flexibility in circuit
design.
Reliability: Rocker switches are known for their durability and long life.
Ease of Use: The rocker mechanism is easy to operate and provides a clear indication of the
switch position.
Compact Size: DPDT rocker switches are available in compact sizes, making them suitable for
space-constrained applications.
Aesthetics: Rocker switches have a modern and sleek appearance, enhancing the aesthetics of
the equipment or panel.

Disadvantages:
Limited Functionality: DPDT switches can only control two circuits and may not be suitable
for applications requiring more complex switching arrangements.
Cost: DPDT switches may be more expensive than single-pole switches, especially for high-
quality models.
Installation: Installing DPDT switches may require some knowledge of electrical wiring and
circuit design.
In summary, a rocker DPDT switch is a versatile and reliable switch that is commonly used in a
variety of applications requiring the control of two separate circuits.

ALUMINIUM ANGLE

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Fig. 1 inch Aluminum Angle

A 1-inch aluminum angle refers to an aluminum extrusion with an L-shaped cross-section, where
each leg of the angle measures 1 inch in length. Aluminum angles are commonly used in
construction, manufacturing, and DIY projects due to their strength, lightweight, and corrosion
resistance.

Key Features:
Size: The size of the aluminum angle is specified by the length of each leg, in this case, 1 inch.
Alloy: Aluminum angles are typically made from aluminum alloys such as 6061 or 6063, which
offer good strength and weldability.
Finish: Aluminum angles may have a mill finish (raw aluminum) or be anodized for improved
corrosion resistance and appearance.
Tolerance: Aluminum angles are manufactured to standard tolerances for dimensions and
straightness.

Advantages of Aluminum Angles:

Strength: Aluminum angles offer good strength-to-weight ratio, making them suitable for
structural applications.
Corrosion Resistance: Aluminum is naturally corrosion-resistant, making aluminum angles
suitable for outdoor and marine environments.
Lightweight: Aluminum is lightweight, which makes handling and installation easier compared
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to steel angles.
Machinability: Aluminum is relatively easy to machine, allowing for custom cuts and shapes.

Applications:
Construction: Used for framing, support brackets, and trim in buildings and structures.
Manufacturing: Used in machinery and equipment for structural support and reinforcement.
DIY Projects: Popular for DIY projects such as shelving, frames, and brackets.
Transportation: Used in automotive and aerospace applications for structural components.
Marine: Used in boat building and marine applications due to its corrosion resistance.

Limitations:
Strength Limitation: Aluminum angles may not be suitable for heavy-duty structural
applications that require high strength.
Cost: Aluminum angles may be more expensive than steel angles, depending on the alloy and
finish.
Surface Finish: The surface finish of aluminum angles may be susceptible to scratching and
damage.
In summary, a 1-inch aluminum angle is a versatile and lightweight structural component that
offers good strength and corrosion resistance, making it suitable for a wide range of applications
in various industries.

LAYOUT

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ACTUAL COMPONENTS

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4. DRAWING

Fig 4.1 Auto cad drawing Fig 4.2 auto cad drawing

TRAILER BASE FRAME 3.2.2 CYLINDER BASE

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5. SPECIFICATIONS

Single acting pneumatic

cylinder PRODUCT
DESCRIPTION
model : MA 25-200
road type : single road
action type : double acting
fluid : air
Bore : 25mm
Stroke : 200mm
Port size : 1/8”
Temperature : -5 c - +70c
Max. working pressure
: 1.0 Mpa
Assure proof pressure : 1.35
Mpa Main material : stainless
steel
Color : stainless color
Cushion type : no cushion
Package content : 1xAir cylinder Fig 5.1 single acting pne0umatic
cylinder

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6. EXPERIMENTATION
6.1. EXPERIMENTATION

Fig 6.1 three axis pneumatic trailer

Working of a modern three axis pneumatic trolley is based on the action of pneumatic cylinder
and rotation of gear. The automobile gear drive is coupled to the compressor so that it store the
compressed air when the vehicle is running. This compressed air is used to activate the pneumatic
cylinder, when the valve is activated. The ram of the pneumatic cylinder act as a lifting the trolley
cabin.

When the dc motor which is connected to the spur gear is operated using a battery , the
gear rotates and thus the rotating disc also rotates. Since the load cabin is directly connected to
the rotating disc , it also rotates.

When the load cabin reaches at the place where the load has to be dumped.

During the forward stroke of cylinder, it pushes truck body upward thus giving necessary
lift for dumping.
So, in the forward stroke of the cylinder the truck is unloaded. In the return stroke of the cylinder
the body of the truck comes to its original position.

6.2 FUTURE SCOPE

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Modification on the current system can be possible. Providing ball and socket joint or universal
joint at the tip of the pneumatic cylinder piston using external or internal compressor.

Introduction of single hydraulic cylinder instead of pneumatic etc can make the system a little more
efficient.

Another change that can be made is to introduce some rollers in between the load
cabin and body of the vehicle. This setup will make the rotation of the load cabin easier and
thus the rotating dick will no longer have to experience the complete load.

Dual stage cylinder can be used.

Wheel staring adopted for easy

handling. Sensor and alarm can
be used.
This arrangement fitted in automated guided vehicle.

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ADVANTAGES

 Air is cheaply and easily available.

 It requires simple maintenance cares
 Checking and cleaning are easy, because of the main parts are screwed.
 Handling is easy.
 Manual power not required
 Repairing is easy.
 Replacement of parts is easy.

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DISADVANTAGES

 Initial cost is high.

 Separate air tank or compressor is required.

 handling of the large air is major problem

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APPLICATION

 All pneumatic dipper applications.

 Material handling unit
 Construction site
 Agriculture

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CONCLUSION

A prototype which exhibits the expected results is developed. With analysis of working
and with the help of pneumatic system. Lifting operation can be easily carried out without much
effort. This mechanism is not only applicable dumping truck but also for various manufacturing
industries. Thus we have developed a three axis pneumatic trolley which helps to know how to
achieve low cost automation. The operating procedure of this system is very simple so, person
can operate. By using more techniques, they can be modified and developed according to the
applications. Further modifications and working limitation will put this work in the main league
of use.

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REFERANCE

1) Industrial fluid power by James Johnson

2) Patent US3817493- hydraulic jack for trailer – Google patent
3) Patent US4711461 – Three axis trailer
4) Master’s thesis, institute of technology, Nirma university, may 2007
5) Automotive industry standards “IAS-053; automotive vehicle-types-technology
6) Automotive industry standards “IAS-093; code of practice for construction and
approval of truck cabs, truck bodies, and trailers.
7) A text book of fluid mechanics and machinery, laxmi publication, new delhi 2000,
by r k bansal
8) Theory of machines, s chand and company ltd, new delhi 2008,by r s khurmi and j k gupta

9) S tiwari, - evolution of empirical relationship between high leval design

parameter with performance cretaria of a ladder type chassis frame

WEBSITE

 www.nptel.com

 www.internationaljournalssrg.org

 www.paperpublications.org

 www.scribd.com

 www.Researchscript.com

 www.ijrasat.com

 www.irjet.net

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