6.

Design calculations:
6.1 Load Capacity:
The maximum load for which the trailer is designed to carry will mostly
determine the strength of the trailer.

It will also determine how strong the trailer should be.

If a trailer is designed for 800Kg it will obviously have much lighter
construction than a trailer designed for 1000Kg, but they should perform
equally well at their rated capacity.

The maximum load capacity which is applied to the EX2000 is 500Kg.

For obtaining maximum strength all the side rails and cross members are
welded together rather than using bolt and nuts.

6.2 Axle location:

The axle should be located behind the load center for stability. Often trailers
have the axle at or just barely behind the center of the bed. The load will be
heaviest at the front. But it is also an indication of weakness. For most
applications, the axle should be noticeably behind the center of the bed, and
for maximum versatility, allow the axle position to be adjusted 32 .
In design of EX2000 the axle is located just behind the centre of the trailer.

6.3 Load distribution:

It is the most common cause of stability concerns. The trailer load should be
reasonably distributed from side to side with at least 10% of the trailer weight
on the hitch. With typical trailers, more weight on the hitch is better for
stability. 15% is usually a good number 33 .

CORRECT WAY TO LOAD THE TRAILER

6.4 Calculations:
The folding trailer chassis is constructed of 2H x 3H galvanized steel with C
channel shape with thickness of 3mm. The cross section of the rail channel is
shown following picture:

6.4.1 Calculation of second moment of area (I):

BD 3 bd3
0.0508 x 0.07623 0.0478 x 0.07023

I=
=

12
12
12
12
= 1.8730 x 10-6 1.3780 x 10-6 = 4.95 x 10-7 mm4

The diagram of the load distribution, acting and reacting forces on folding
trailer and tires are shown in following picture:

The diagram shows a uniformly distributed load 4910 N/m across the whole
span.
The total load carried = 4910 N/m x 1m = 4910 N

The bending moment M is found by treating the distributed load acting at its
centre of gravity.
M = (2455 x 0.5) [(4910 x 0.5) x 0.25] = 613.75 Nm

6.4.2 Calculation of bending stress 34 :

= My
I

613.75 x 0.0381
= 47.2 MN/m 2
-7
4.95 x 10

6.4.3 Calculation of Factors of Safety 35 :

Ultimate Strength for Steel is 1860 x 10 6 N/m 2 .

Material Strength (N

Factors of Safety =

6
)
m 2 = 1860 x 10 = 39.4
47.2 x 10 6
Working Stress (N 2 )
m

Result: As factor of safety is bigger than 1 it will not break and will withstand
the load.

6.4.4 Calculation of Double Shear Stress:

4910
= 2455 N
2
D is the diameter of suspension unit connecting end to hub which is 25.4mm.

F=

2455
F
=
= 2423731 N 2
m
2A
2 x x 0.01272

Factors of safety =
not break.

1860 x 10 6
= 767.41 which is bigger than 1 therefore it will
2423731

6.4.4 Calculation of Shear stress on cross member:

F = 4910 N
A = area of the cross section of the rail channel = 0.003 x 0.0508 + 0.003 x
0.0732 + 0.0478 x 0.003 = 5.154 x 10 4 m 2
A = 5.154 x 10 4 m 2

4910
= 9526581.3 N 2
m
5.154 x 10 - 4

Factors of safety =

1860 x 10 6
= 195.37 which is bigger than 1 therefore
9.52 x 10 6

it will not break.

6.4.5 Calculation of Shear stress in front of folding trailer:

It is important that the tongue be pressing down on the hitch, but not
exceeding a downward force of 10% of overall load. The diagram of the forces
applied on trailer is shown as below:

Force applied on hitch = 10% force applied by overall load = 10% x 500 x 9.82
= 491 N
Force applied on each tires = 2209.5 N

Cross section area of hitch connection to tow bar is:

The diameter of each hole on hitch is 12mm. therefore the cross section area
of the hole = x 0.0062 = 1.1304 x 10 4 m 2
=

491
= 2205671 N
2 x 1.1304 x 10 -4

Factors of safety =

1860 x 10 6
= 845.45 which is bigger than 1 so it will not
2.2 x 10 6

break.

Final result:
By applying maximum load of 500 Kg the EX2000 folding trailer will
withstand.

7. Safety and ease of use (EX2000 folding trailer) 36 :

7.1 Special notice for coupler:

A 1-7/8 ball hitch should be used on the towing vehicle. Then trigger is
pulled and handle lifted. Coupler is placed over trailer hitch ball and
pushed down on handle until trigger is locked in place.

In order to make sure that there is no any play between the ball and
coupler the coupler is pulled up and down several times.

If there is a play, the adjustment nut can be tightened until no play is

present.

To reduce friction between the ball hitch and coupler a layer of

multipurpose lithium grease over ball hitch.

7.2 Towing vehicle:

The vehicle which is supposed to tow must be capable of doing the job.

Excess speed is the second most important cause of car-trailer

accidents. Maximum speed for all passenger cars towing trailers is 45
M.P.H.

7.3 Safety chains:

Safety chains must be used.

Safety chains must be attached to towing vehicle with the same length
for each side.

Chains should not be dragged on ground.

7.4 Loading:

The trailer must not be overloaded. Maximum load is 500 Kg.

Load must be distributed evenly from side to side with 60% of the load

forward to the axle.

It is important that the tongue be pressing down on the hitch.

It is advisable to reduce weight in car trunk and rear seat areas by

amount of tongue weight of your trailer.

It is against the law to carry passengers in the back of any trailer

7.5 Lighting:

Lighting must be checked before each use and every 100 miles to be
sure that the lights are working properly.

Wires must be checked for good connections and wearing of insulation

Bulbs supplied with this trailer are 12 volts.

Bulbs used in tail light are: Number 1157 Stop and Tail.

Bulb for clearance is: Number 1895 which is a standard number.

7.6 Tires:

The tires must be checked for wear and proper inflation before each
use and every 100 miles.

Tire pressure should be kept at 60 PSI.

lug nuts must be checked

7.7 Operation:

The driver must be aware of controlling the towing vehicle-trailer

combination on the highway under all condition.

It is advisable to carry emergency flares, and fire extinguisher if

required for operation in you state.

It is desirable to carry spare bulbs and fuses.

7.8 Jockey & Props: BSJ34B Autow 34mm Sliding Jockey

Autow 34mm light-duty sliding jockey, fully plated, 150x45mm plastic centre
wheel with solid rubber Tyre, complete with BC34L clamp, pad and handle,
ideal for small domestic trailers. It enables the folding trailer to withstand in
service conditions.

7.9 Maintenance:

The trailer, coupler, ball and hitch must be checked every 200 miles.

The hitch and ball must be inspected for damage every day use.

To prevent bearing damage, wheel bearing should be disassembled

and repacked with a good grade of wheel bearing with a good grade of
wheel bearing grease every 2000 3000 miles or yearly.

Safety chain must be checked for wear.

8. Ergonomic and anthropometric:

All edges are rounded off to avoid injury or cut while carrying the trailer
or changing the parts.

Couplings: The new generation couplings are designed for ease of

operation and safety. The new low profile, ergonomic handle, which
provides extra clearance for tow vehicles with rear opening doors, also
gives a reassuring audiable signal once successful attachment has
been made.

The main chassis is made of C channel profile which makes the folder
light and makes it easy for the user to fold the rear bench over the front
bench by using minimum energy.

All the wholes and screws are standard and can be unscrewed and
screwed easily.

The rear bench handgrip has a diameter of approximately 4 cm.

When carrying folding trailer in a storage mode the stature of men aged
18 to 40 percentiles 95th is 1846mm and for women aged 18 to 40
percentiles 95th is 1758mm 37 .

9. Trailer Licensing Notice:

The M.C.O. (Manufactures Certificate of Origin) supplied with the trailer
should be filled out and signed by the dealer.

References/Bibliography

Books

The Engineering Design Process B.Hawkes/R.Abinett Page 116

Online Resources

www.motorcyclecarrier.net/motorcycle_trailer_stinger.html

www.redtrailers.com/showtrailer.asp?id=1

www.ciao.co.uk/duuo_dual_purpose_easy_store_trailer_6376632

www.sportutilitytrailers.com/magneta/ltb2.htm

www.sportutilitytrailers.com/fishing-boat -trailer.htm

http://images.google.com/images?imgurl=http://www.ssbtractor.com

http://images.google.com/imgres?imgurl=http://www.dktrailers.com/trail
ers/

www.dktrailers.com/trailers/

www.dktrailers.com/trailers/livestock

www.autow.co.uk/trailer_parts.html

www.synthx.com/articles/trailer-stability.html

www.synthx.com/articles/trailer-choice.html

www.sportutilitytrailers.com/longchih/749tc.htm

www.autow.co.uk

Sources of images

www.motorcyclecarrier.net/motorcycle_trailer_stinger.html

www.redtrailers.com/showtrailer.asp?id=1

www.ciao.co.uk/duuo_dual_purpose_easy_store_trailer_6376632

www.sportutilitytrailers.com/snowmobile-trailer.htm

www.sportutilitytrailers.com/fishing-boat-trailer.htm

http://images.google.com/imgres?imgurl=http://www.ssbtractor.com

www.dktrailers.com/trailers

www.dktrailers.com/trailers/livestock

Contents

1.

Existing towed trailers design

Page 1

1.1

Motorcycle folding trailer

Page 1

1.2

Folding trailer

Page 2

1.3

Easy store trailer

Page 4

1.4

Snowmobile Trailers and

Mounting Brackets

Page 6

1.5

Fishing boat trailers

Page 7

1.6

Dump Trailer

Page 8

1.7

Tilt bed Trailers

Page 9

1.8

Heavy duty equipment trailers

Page 10

1.9

Reel Trailers and poles

Page 11

1.10 Livestock Trailers

2.

2.1

Page 13

Sketches and concept of designs for a

new folding trailer

Page 14

Introduction

Page 14

2.2

Folding mechanism

Page 14-15

2.3

Sketches

Page 16 21

3.

Bill of materials

Page 23

Technical drawings

Page 25-45

3.1

Standard parts

Page 46

4.

Mass properties

Page 49-59

5.

Design and assembly process

Page 60-63

5.1

Final solution

Page 66

5.2

Exploded view

Page 67

Design Calculation

Page 68

6.1

Load Capacity

Page 68

6.2

Axle location

Page 68

6.3

Load distribution

Page 69

6.4

Calculations

Page 69

6.

6.4.1 Calculation of second moment of area

Page 70

6.4.2 Calculation of bending stress

Page 71

6.4.3 Calculation of Factors of Safety

Page 71

6.4.4 Calculation of Double Shear Stress

Page 71

6.4.5 Calculation of shear stress

in front of trailer

7.

Page 72

Safety and ease of use

(EX2000 folding trailer)

Page 74

7.1

Special notice for coupler

Page 74

7.2

Towing vehicle

Page 74

7.3
7.4

Safety chains
Loading

Page 74
Page 74

7.5

Lighting

Page 75

7.6

Tires

Page 75

7.7

Operation

Page 75

7.8

Maintenance

Page 76

8.

Ergonomic and anthropometric

Page 77

9.

Trailer Licensing Notice

Page 77

10.

Reference/Bibliography

Page 78