KHAIRUL AZRI BIN NGADIMEN

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1 2 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

2 3 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:

3 4 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:

4 5 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.

5 6 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.

6 7 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.

7 8 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.

8 9 TABLE OF CONTENTS SUPERVISOR S DECLARATION STUDENT S DECLARATION DEDICATION ACKNOWLEDGEMENTS ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES Page ii iii iv v vi vii viii xi xii CHAPTER 1 INTRODUCTION 1.1 Project Name Project Synopsis Project Background Problem Statement Project Objective General Objective Specific Objective Project Scope Project Gantt Chart Flow Chart 6 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction Technical Review Product A Product B Product C 10

9 Product D 11 CHAPTER 3 METHDOLOGY 3.1 Project Flow Chart Design Drawing Sketching And Drawing Selection Concept A Concept B Concept C Concept Generation And Evaluation Computer Aided Design Drawing Analysis of Design First Design Second Design Result of Failure Analysis Result of Failure for First Analysis Result of Failure for Second Analysis Bill of Material Fabrication Process Process Involved Gathering Material Measuring Cutting Material Joining Process Grinding Process Drilling Process Finishing Process 27 CHAPTER 4 TESTING, RESULT AND DISCUSSION

10 Final Product Result after Finishing Testing Test 1(Maximum load of 200kg) Test 2(Functional Trolley with Extra Feature) Result and Analysis Product Specification Discussion Type of Defect Gap Bead Problem in Progress Literature Review Problem Fabrication Problem Safety Rubber Lid 35 CHAPTER 5 CONCLUSION AND RECOMMENDATIONS 5.1 Introduction Conclusion Recommendation 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

11 12 LIST OF TABLES Table No. Page 3.1 Table of Pugh concept Bill of material Product specification 32

12 13 LIST OF FIGURES Figure No. Page 2.1 Product A Product B Product C Product D Flow chart Concept A Concept B Concept C Concept D Solid work picture Analysis force at the side Analysis force at the center Result for first analysis Result for second analysis Type of material Measuring dimension Cutting material Joinning process Grinding process Drilling process Finishing process 27

13 Complete view Complete view (explode view) Testing of the maximum load Testing of the maximum load Testing of multiuse Testing of multiuse Testing of multiuse Product gap Bead Rubber lid 36

14 15 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.

15 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.

16 PROJECT OBJECTIVE Project objective is dividing into two objectives. First is general objective and second is the specific objective for the project 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 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.

17 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.

18 PROJECT GANTT CHART WEEK TASK 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

19 FLOW CHART START Literature Review Research Existing Product Brainstorming and Idea Development Concept Selection YES NO Design on concept (Sketch) Analysis of Design (Cost and Failure) Detail Design YES NO Fabrication Prototype Product

20 21 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.

21 TECHNICAL REVIEW 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.

22 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).

23 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.

24 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.

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