LOW COST HEAVY WEIGHT TRANSPORTING VEHICLE

SYNOPSIS

While shifting house, it will be very difficult for the persons to lift the heavy things to

upstairs or to the downstairs. The heavy household consumables include grinder, washing

machine, refrigerator, big cup boards, air conditioners etc., it requires at least four to five

people to lift it and transfer it to other places for shifting the houses. So in order to overcome

this problem, we have designed a prototype which can lift the heavy household items without

any hesitation and with ease. Moreover, only one person is enough to lift the heavy items either

from upstairs to downstairs or from downstairs to upstairs.

INTRODUCTION

Material handling involves short-distance movement within the confines of a building or

between a building and a transportation vehicle.[1] It utilizes a wide range of manual, semi-

automated, and automated equipment and includes consideration of the protection, storage, and

control of materials throughout their manufacturing, warehousing, distribution, consumption,

and disposal.[2] Material handling can be used to create time and place utility through the

handling, storage, and control of material, as distinct from manufacturing, which creates form

utility by changing the shape, form, and makeup of material.

Role of Material Handling

Material handling plays an important role in manufacturing and logistics, which together

represent over 20% of the U.S. economy.[4] Almost every item of physical commerce was

transported on a conveyor or lift truck or other type of material handling equipment in

manufacturing plants, warehouses, and retail stores.[5] While material handling is usually

required as part of every production worker's job, over 650,000 people in the U.S. work as

dedicated "material moving machine operators" and have a median annual wage of $31,530

(May 2012).[6] These operators use material handling equipment to transport various goods in

a variety of industrial settings including moving construction materials around building sites

or moving goods onto ships.

Design of material handling systems

Material handling is integral to the design of most production systems since the efficient flow

of material between the activities of a production system is heavily dependent on the

arrangement (or layout) of the activities. If two activities are adjacent to each other, then

material might easily be handed from one activity to another. If activities are in sequence, a

conveyor can move the material at low cost. If activities are separated, more expensive
industrial trucks or overhead conveyors are required for transport. The high cost of using an

industrial truck for material transport is due to both the labor costs of the operator and the

negative impact on the performance of a production system (e.g., increased work in process)

when multiple units of material are combined into a single transfer batch in order to reduce the

number of trips required for transport.

The unit load concept

A unit load is either a single unit of an item, or multiple units so arranged or restricted that they

can be handled as a single unit and maintain their integrity. Although granular, liquid, and

gaseous materials can be transported in bulk, they can also be contained into unit loads using

bags, drums, and cylinders.[8] Advantages of unit loads are that more items can be handled at

the same time (thereby reducing the number of trips required, and potentially reducing handling

costs, loading and unloading times, and product damage) and that it enables the use of

standardized material handling equipment. Disadvantages of unit loads include the negative

impact of batching on production system performance, the time spent forming and breaking

down the unit load, the cost of containers/pallets and other load restraining materials used in

the unit load, and the cost of returning empty containers/pallets to their point of origin.

In-process handling
Unit loads can be used both for in-process handling and for distribution (receiving, storing, and

shipping). Unit load design involves determining the type, size, weight, and configuration of

the load; the equipment and method used to handle the load; and the methods of forming (or

building) and breaking down the load. For in-process handling, unit loads should not be larger

than the production batch size of parts in process. Large production batches (used to increase

the utilization of bottleneck activities) can be split into smaller transfer batches for handling

purposes, where each transfer batch contains one or more unit loads, and small unit loads can

be combined into a larger transfer batch to allow more efficient transport.

Types of material handling

Manual handling

Manual handling refers to the use of a worker’s hands to move individual containers by lifting,

lowering, filling, emptying, or carrying them. It can expose workers to physical conditions that

can lead to injuries that represent a large percentage of the over half a million cases of

musculoskeletal disorders reported in the U.S. each year, and often involve strains and sprains

to the lower back, shoulders, and upper limbs.[12] Ergonomic improvements can be used to

modify manual handling tasks to reduce injury. These improvements can include reconfiguring

the task and using positioning equipment like lift/tilt/turn tables, hoists, balancers, and

manipulators to reduce reaching and bending. The NIOSH (National Institute for Occupational

Safety and Health) 1991 Revised Lifting Equation[13] can be used to evaluate manual lifting

tasks. Under ideal circumstances, the maximum recommended weight for manual lifting to

avoid back injuries is 51 lb (23.13 kg). Using the exact conditions of the lift (height, distance

lifted, weight, position of weight relative to body, asymmetrical lifts, and objects that are

difficult to grasp), six multipliers are used to reduce the maximum recommended weight for

less than ideal lifting tasks.

Automated Handling

Whenever technically and economically feasible, equipment can be used to reduce and

sometimes replace the need to manually handle material. Most existing material handling

equipment is only semi-automated because a human operator is needed for tasks like

loading/unloading and driving that are difficult and/or too costly to fully automate, although

ongoing advances in sensing, machine intelligence, and robotics have made it possible to fully

automate an increasing number of handling tasks

LITERATURE REVIEW

Literature review areas of research considered in the past, to be explained the approaches used & the

new ideas. It is an assignment of previous task done by some authors and collection of information or

data from research papers published in journals to progress our task. It is a way through which we can

find new ideas, concept. There is lot of literatures published before on the same task; some reference

papers are taken into consideration from which idea of the project is taken, the other reference will

we discussed later.

A. Work Safe Victoria:

In this title “A Guide to Manual Handing in the Food Industry” explains material handling in

food industries. Hazards while handling material in food industries. Information contained in

this Guide is derived from the 2003 guide Manual Handling in the Food Industry and from a

workshop held during Work Safe Week2005. The workshop brought together unions, workers,

industry associations, employers, training organizations, ergonomists, industry safety

consultants and health and safety representatives to share ideas for addressing the risks in

the food industry due to manual handling tasks. The Guide demonstrates both Work Safe’s

and the industry’s expectations on how to best reduce the risk of musculoskeletal disorders

arising from manual handling in the food industry

B. Work Cover: In this title “ Manual Handling Resources” Explain tAustralia Post is one of the largest

road transport operators in Australia, handling tens of thousands of mailbags, letter trays and other

items every day. In the past these mail bags and letter trays were handled manually at post offices

and mail centres. This often required repetitive bending, twisting and reaching while lifting loads of

up to 16 kg into and out of trucks and vans. This manual handling task has now been significantly

reduced with the introduction of the Folding Unit Load Device (FULD), a stackable steel mesh container

that is lifted and moved by forklift, even at centres where there is no loading dock. A further innovation

is a pneumatically operated device developed by Australia Post (NSW) for securing the FULDs in trucks.

The device is basically a steel channel, suspended from the roof of the truck that descends to clamp
down the FULDs in the truck. The better use material handling equipment for the different application

like in cleaning of floor, storing easy method etc. Also explain how to reduce work load and maximize

safety.

C. Environment, Health, and Safety: In paper title “Safe Manual Material Handling” by University Of

California explain frequent lifting, carrying, pushing, pulling, lowering and raising materials by hand.

These job tasks are often referred to as manual materials handling. Staff who lift or perform other

materials handling tasks may be at risk for back or other injuries.

D. Rajib Kumar Bhattacharjya: In this title “Engineering Mechanics“ Explain Truss , forces , torque and

friction in Engineering mechanic. E. European Agency for Safe and Health in His Title “Hazard and risks

associated with manual handling in the workplace” Explain the risk associated with manual material

handling at work place. Also explain back injury due to load handling.

F. Health and Safety Executive: In His title “Making the best use of lifting and handling aids” Explain

the how to use the material handling equipment for various application in industries. by–

www.hse.gov.uk/pubns/indg398.htm.

G. Clyde Material Handling: In His title “Material Handling Solution for the Food & Pharmaceutical

Industries” Explain the use of material handling equipment in pharmaceutical industries. And also

explain requirement of in material handling in pharmaceutical industries.

H. California Department of Industrial Relations: In this Title “Manual Material Handling” written for

managers and supervisors in industries that involve the manual handling of containers. It offers

suggestions to improve the handling of rectangular, square, and cylindrical containers, sacks, and bags.

“Improving Manual Material Handling in Your Workplace” lists the benefits of improving your work

tasks. It also contains information on risk factors, types of Ergonomic improvements, and effective

training and sets out a four-step proactive action plan. The plan helps you identify problems, set

priorities, make changes, and follow up.

I. Worksafe Victoria in This Title “Safety by Design”: Explain The transportation of goods plays a major

role in Australiaís national and international activities. With so much of our wealth on the move,
transport related activities contribute significantly to Australiaís work injury toll. More than 80% of

severe injuries among transport workers are sustained while not driving.These injuries are related to

manual handling. Severe sprains and strains can happen when loading and unloading a truck as well

as slips, trips and falls that occur when getting on and off a vehicle. Many of these injuries are serious

and disabling, and in some cases, fatal. But there are ways to reduce the risks. This booklet helps to

identify some of the potential risks and provides solutions and tips to help reduce injuries in the

transport industry.
The following are the components of low cost heavy weight transporting vehicle

1. BASE

2. SHAFTS

3. BEARINGS

4. GEARS

5. DISK

7. CONNECTING ROD

8. POWER DRILL
TABLE OF MATERIAL USED

SR. NO. ITEMS QUANTITY MATERIAL

1 ANGLE 12 FT MILD STEEL
2 BOARD 1 NOS. WOOD
3 SHAFT 4 FT MILD STEEL
4 BEARINGS 4 NOS. ----
5 DISK 1 NOS. MILD STEEL
6 CONNECTING ROD 1 NOS. MILD STEEL
7 WHEEL 4 NOS MILD STEEL

TABLE – 4.1
4.1 BASE

The base is the rectangular piece of plywood. It is the stationary & rigid part of the machine.
Since machine consist of rotating parts which often produces vibrations when rate of excessive
vibrations produced by the rotating parts of the machine. It also provides the rigid support to
the rotating part of the machine.

Figure 4.1 PLYWOOD BASE

4.2 SHAFTS

A shaft is a rotating machine element which is used to transmit power from one place to
another. The power is delivered to the shaft by some tangential force and the resultant torque
(or twisting moment) set up within the shaft permits the power to be transferred to various
machines linked up to the shaft. In order to transfer the power from one shaft to another, the
various members such as pulleys, gears etc., are mounted on it. These members along with the
forces exerted upon them causes the shaft to bending. In other words, we may say that a shaft
is used for the transmission of torque and bending moment. The various members are mounted
on the shaft by means of keys or splines.
 Figure 4.2 STEEL SHAFT

1. The shafts are usually cylindrical, but may be square or cross-shaped in section. They
are solid in cross-section but sometimes hollow shaft are also used.

2. An axle, though similar in shape to the shaft, is a stationary machine element and is
used for the transmission of bending moment only. It simply acts as a support for some rotating
body such as hoisting drum, a car wheel or a rope sheave.

3. A spindle is short shaft that imparts motion either to a cutting tool (e.g. drill press
spindles) or to a work piece (e.g. lathe spindles).

4.2.1 MATERIAL USED FOR SHAFTS

The material used for shafts should have the following properties:

1. It should have high strength.

2. It should have good mach inability.

3. It should have low notch sensitivity factor.

4. It should have good heat treatment properties.

5. It should have high wear resistant properties.

The material used for ordinary shafts is carbon steel of grades 40C8, 45C8, 50C4, and 50C12.

The mechanical properties of these grades of carbon steel are given in the following table.
 Table: Mechanical properties of steels used for shafts.

Indian standard Ultimate tensile strength, Yield strength (MPa)

designation (MPa)

40C8 560-670 320

40C8 610-700 350

50C4 640-760 370

50C12 700 Min. 390

TABLE – 4.2

When a shaft of high strength is required, then alloy steel such as nickel, nickel-chromium or
chrome-vanadium steel is used.

4.2.2 MANUFACTURING OF SHAFTS

Shafts are generally manufactured by hot rolling and finished to size by cold drawing or turning
and grinding. The cold rolled shafts are stronger than hot rolled shafts but with higher resident
stresses. The residual stresses may cause distortion of the shaft when it is machined, especially
when slots or keyways are cut. Shafts of larger diameter are usually forged and turned to size
in a lathe.

4.2.3 TYPES OF SHAFTS

The following two types of shafts are important from the subject point of view:

1. Transmission shafts: These shafts transmit power between the source and the
machines absorbing power. The counter shafts, line shafts, over head shafts and all factory
shafts are transmission shafts. Since these shafts carry machine parts such as pulleys, gears,
etc., therefore they are subjected to bending in addition to twisting.

2. Machine shafts: These shafts form an integral part of the machine itself. The
crank shaft is an example of machine shaft.

4.2.4 STANDARD SIZES OF TRANSMISSION SHAFTS

The standard sizes of transmission shafts are:

25mm to 60mm with 5mm steps; 60mm to 110mm steps; 110mm to 140 mm with 15mm steps;
and 140mm to 500mm with 20mm steps.

The standard length of the shafts is 5m, 6m and 7m.

4.2.5 DESIGN OF SHAFTS

The shafts may be designed on the basis of

1. Strength, and

2. Rigidity and stiffness.

In designing shafts on the basis of strength, the following cases may be considered:

(a) Shafts Subjected to twisting moment or torque only.

(b) Shafts subjected to bending moment only.

(c) Shafts subjected to combined moment only.

(d) Shafts subjected to axial loads in addition to combined torsional and bending loads.
We shall now discuss the above cases, in detail, in the following pages

4.3 DISK

The disk is that rotating element of the mechanism which converts the rotating motion into
sliding motion. The disk is the main part of the mechanism. It also works as fly wheel which
store energy in power stock & provide energy in returns stock. It is also made up o mild steel.

4.3.1 Rotary motion to translator motion

The conversion from rotary motion of the disk to the translator motion of the piston &
connecting rod is achieved by placing an eccentric point on the disk shown below
 Figure 4.3 DISK

With the rotation of disk around its centre the point revolute around that centre of disk. Hence
we can say that rotation of disk produces revolution of eccentric point which forces the piston
forward & background by the mean of connecting rod and connecting rod hence stock is
produced by the piston.

Figure 4.4 ECCENTRIC POINT

1.4 THE CONNECTING ROD

The connecting rod is that element of the mechanism which transfer motion from one end of
the connecting rod is connected to the end of the slide piston while the other end is connected
to the disk. The material used for the connecting rod is mild steel.

4.4.1 Calculating the length of connecting Rod.

The length of connecting rod should never be less than the diameter of the stroke length
generated by the disk is equals to the twice the radius of the disk i.e. diameter.

The second factor that matters for the length of the connecting road is the space (or distance)
between the rotating part and the sliding part. In our case it’s the distance between the disk &
the end of the sliding piston so the total length of the connecting rod is the sum of the distance
between end of the sliding piston & the disk eccentric point & the diameter of the disk.

4.5 BEARINGS

Figure 4.5 BEARINGS

4.5.1 INTRODUCTION

The term "bearing" is derived from the verb "to bear", a bearing being a machine element that
allows one part to bear (i.e., to support) another.

A bearing is a device that is used to enable rotational or linear movement, while reducing
friction and handling stress. Resembling wheels, bearings literally enable devices to roll, which
reduces the friction between the surface of the bearing and the surface it’s rolling over. It’s
significantly easier to move, both in a rotary or linear fashion, when friction is reduced—this
also enhances speed and efficiency.

Also a bearing is a machine element that constrains relative motion between moving parts to
only the desired motion. The design of the bearing may, for example, provide for
free linear movement of the moving part or for free rotation around a fixed axis; or, it
may prevent a motion by controlling the vectors of normal forces that bear on the moving
parts. Bearings are classified broadly according to the type of operation, the motions allowed,
or to the directions of the loads (forces) applied to the parts.

4.5.2 WORKING –

In order to serve all these functions, bearings make use of a relatively simple structure: a ball
with internal and external smooth metal surfaces, to aid in rolling. The ball itself carries the
weight of the load—the force of the load’s weight is what drives the bearing’s
rotation. However, not all loads put force on a bearing in the same manner. There are two
different kinds of loading: radial and thrust.

A radial load, as in a pulley, simply puts weight on the bearing in a manner that causes the
bearing to roll or rotate as a result of tension. A thrust load is significantly different, and puts
stress on the bearing in an entirely different way. If a bearing (think of a tire) is flipped on its
side (think now of a tire swing) and subject to complete force at that angle (think of three
children sitting on the tire swing), this is called thrust load. A bearing that is used to support a
bar stool is an example of a bearing that is subject only to thrust load.
Many bearings are prone to experiencing both radial and thrust loads. Car tires, for example,
carry a radial load when driving in a straight line: the tires roll forward in a rotational manner
as a result of tension and the weight they are supporting. However, when a car goes around a
corner, it is subject to thrust load because the tires are no longer moving solely in a radial
fashion and cornering force weighs on the side of the bearing.

4.5.3 TYPES OF BEARINGS

There are numerous different kinds of bearings that are designed to handle radial load, thrust
load, or some combination of the two. Because different applications require bearings that are
designed to handle a specific kind of load and different amounts of weight, the differences
between types of bearings concern load type and ability to handle weight.

1) BALL
BEARINGS

6)
2) ROLLER
SPECIALIZED
BEARINGS
BEARINGS

TYPES OF
BEARINGS

5) TAPERED 3) BALL
ROLLER THRUST
BEARINGS BEARINGS

4) ROLLER
THRUST
BEARINGS

Figure 4.6 TYPES OF BEARINGS

1) BALL BEARINGS

Ball bearings are extremely common because they can handle both radial and thrust loads, but
can only handle a small amount of weight. They are found in a wide array of applications, such
as roller blades and even hard drives, but are prone to deforming if they are overloaded.
 Figure 4.7 BALL BEARINGS

APPLICATIONS

1) Rolling friction is provided by a ball.

2) Low friction, high speed, light to medium loading.
3) Light and general machine applications.
4) Commonly found in fans, roller blades, wheel bearings, and under hood applications
on cars etc.

2) ROLLER BEARINGS

Roller bearings are designed to carry heavy loads—the primary roller is a cylinder, which
means the load is distributed over a larger area, enabling the bearing to handle larger amounts
of weight. This structure, however, means the bearing can handle primarily radial loads, but is
not suited to thrust loads. For applications where space is an issue, a needle bearing can be
used. Needle bearings work with small diameter cylinders, so they are easier to fit in smaller
applications.

Figure 4.8 ROLLER BEARINGS

APPLICATIONS

1) In this the rolling function is provided by a cylinder of some kind. May also be referred
to as needle roller bearings (where length is much greater than diameter)
2) Low friction, medium to heavy radial loading.
 3) Commonly found in general machine applications including gearboxes and
transmissions, machine tool construction equipment.

1) BALL THRUST BEARINGS

These kinds of bearings are designed to handle almost exclusively thrust loads
in low-speed low-weight applications. Bar stools, for example, make use of ball thrust
bearings to support the seat.

Figure 4.9 BALL THRUST BEARINGS

2) ROLLER THRUST BEARINGS

Roller thrust bearings, much like ball thrust bearings, handle thrust loads. The difference,
however, lies in the amount of weight the bearing can handle: roller thrust bearings can
support significantly larger amounts of thrust load, and are therefore found in car
transmissions, where they are used to support helical gears. Gear support in general is a
common application for roller thrust bearings.

Figure 4.10 ROLLER THRUST BEARINGS

3) TAPERED ROLLER BEARINGS

This style of bearing is designed to handle large radial and thrust loads—as a result of their
load versatility, they are found in car hubs due to the extreme amount of both radial and thrust
loads that car wheels are expected to carry.

Figure 4.11 TAPERED ROLLER BEARINGS

APPLICATIONS

1) A tapered version of a roller bearing is used for combined axial and radial loads, such
as in wheel applications on truck.
2) Commonly found in heavy industrial, truck and wheel applications with combined
radial and axial loads. Some examples are manual transmissions, gearboxes, power
generation and other process equipment.

4) SPECIALIZED BEARINGS
There are, of course, several kinds of bearings that are manufactured for specific
applications, such as
I. MAGNETIC BEARINGS are found in high-speed devices because it has no
moving parts—this stability enables it to support devices that move
unconscionably fast.
 Figure 4.12 MAGNETIC BEARINGS

II. GIANT ROLLER BEARINGS are used to move extremely large and heavy
loads, such as buildings and large structural components.

Figure 4.13 GIANT ROLLER BEARINGS

Wheels

A wheel is a circular component that is intended to rotate on an axle bearing. The wheel is one
of the main components of the wheel and axle which is one of the six simple machines. Wheels,
in conjunction with axles, allow heavy objects to be moved easily facilitating movement or
transportation while supporting a load, or performing labor in machines. Wheels are also used
for other purposes, such as a ship's wheel, steering wheel, potter's wheel and flywheel.

Common examples are found in transport applications. A wheel greatly reduces friction by
facilitating motion by rolling together with the use of axles. In order for wheels to rotate,
a moment needs to be applied to the wheel about its axis, either by way of gravity or by the
application of another external force or torque.

Material handling equipment is mechanical equipment used for the movement, storage, control

and protection of materials, goods and products throughout the process of manufacturing,

distribution, consumption and disposal.The different types of material handling equipment can be

classified into four major categories: transport equipment, positioning equipment, unit load

formation equipment, and storage equipment.

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed
below.

1. PROPERTIES

The material selected must posses the necessary properties for the proposed

application. The various requirements to be satisfied

Can be weight, surface finish, rigidity, ability to withstand environmental

attack from chemicals, service life, reliability etc.

The following four types of principle properties of materials decisively

affect their selection

 Physical

 Mechanical

 From manufacturing point of view

 Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific gravity,

electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

 Compressive shear, bending, torsion and buckling load, fatigue resistance,

impact resistance, elastic limit, endurance limit, and modulus of elasticity,

hardness, wear resistance and sliding properties.

The various properties concerned from the manufacturing point of view

are,

 Cast ability

 Weld ability

 Surface properties

 Shrinkage

 Deep drawing etc.

2. MANUFACTURING CASE

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may

demand the use of special materials.

3. QUALITY REQUIRED

This generally affects the manufacturing process and ultimately the

material. For example, it would never be desirable to go casting of a less number

of components which can be fabricated much more economically by welding or

hand forging the steel.

4. AVAILABILITY OF MATERIAL
 Some materials may be scarce or in short supply, it then becomes

obligatory for the designer to use some other material which though may not be

a perfect substitute for the material designed. The delivery of materials and the

delivery date of product should also be kept in mind.

5. SPACE CONSIDERATION

Sometimes high strength materials have to be selected because the forces

involved are high and space limitations are there.

6. COST

As in any other problem, in selection of material the cost of material plays

an important part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-maintenance

of the designed part are involved in the selection of proper materials.

Welding

Welding is a fabrication or sculptural process that joins materials,

usually metals or thermoplastics, by causing fusion, which is distinct from lower temperature
metal-joining techniques such as brazing and soldering, which do not melt the base metal. In
addition to melting the base metal, a filler material is typically added to the joint to form a pool
of molten material (the weld pool) that cools to form a joint that is usually stronger than the
base material. Pressure may also be used in conjunction with heat, or by itself, to produce a
weld.

Although less common, there are also solid state welding processes such as friction
welding or shielded active gas welding in which metal does not melt.

Some of the best known welding methods include:

 Oxy-Acetylene gas welding - one of the most common of the Oxy-Fuel welding process,
uses pressurized oxygen and acetylene to create a flame hot enough to melt and fuse metals.
 Shielded metal arc welding (SMAW) – also known as "stick welding or electric welding",
uses an electrode that has flux around it to protect the weld puddle. The electrode holder
holds the electrode as it slowly melts away. Slag protects the weld puddle from
atmospheric contamination.
 Gas tungsten arc welding (GTAW) – also known as TIG (tungsten, inert gas), uses a non-
consumable tungsten electrode to produce the weld. The weld area is protected from
atmospheric contamination by an inert shielding gas such as argon or helium.
 Gas metal arc welding (GMAW) – commonly termed MIG (metal, inert gas), uses a wire
feeding gun that feeds wire at an adjustable speed and flows an argon-based shielding gas
or a mix of argon and carbon dioxide (CO2) over the weld puddle to protect it from
atmospheric contamination.
 Flux-cored arc welding (FCAW) – almost identical to MIG welding except it uses a special
tubular wire filled with flux; it can be used with or without shielding gas, depending on the
filler.
 Submerged arc welding (SAW) – uses an automatically fed consumable electrode and a
blanket of granular fusible flux. The molten weld and the arc zone are protected from
atmospheric contamination by being "submerged" under the flux blanket.
 Electroslag welding (ESW) – a highly productive, single pass welding process for thicker
materials between 1 inch (25 mm) and 12 inches (300 mm) in a vertical or close to vertical
position.
 Electric resistance welding (ERW) - a welding process that produces coalescence of laying
surfaces where heat to form the weld is generated by the electrical resistance of the
material. In general, an efficient method, but limited to relatively thin material.

Many different energy sources can be used for welding, including a gas flame, an electric arc,
a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding
may be performed in many different environments, including in open air, under water, and
in outer space. Welding is a hazardous undertaking and precautions are required to
avoid burns, electric shock, vision damage, inhalation of poisonous gases and fumes, and
exposure to intense ultraviolet radiation.

Until the end of the 19th century, the only welding process was forge welding,
which blacksmiths had used for centuries to join iron and steel by heating and hammering. Arc
welding and oxyfuel welding were among the first processes to develop late in the century, and
electric resistance welding followed soon after. Welding technology advanced quickly during
the early 20th century as the world wars drove the demand for reliable and inexpensive joining
methods. Following the wars, several modern welding techniques were developed, including
manual methods like SMAW, now one of the most popular welding methods, as well as semi-
automatic and automatic processes such as GMAW, SAW, FCAW and ESW. Developments
continued with the invention of laser beam welding, electron beam welding, magnetic pulse
welding (MPW), and friction stir welding in the latter half of the century. Today, the science
continues to advance. Robot welding is commonplace in industrial settings, and researchers
continue to develop new welding methods and gain greater understanding of weld quality.

ARC

These processes use a welding power supply to create and maintain an electric arc between an
electrode and the base material to melt metals at the welding point. They can use
either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes.
The welding region is sometimes protected by some type of inert or semi-inert gas, known as
a shielding gas, and filler material is sometimes used as well.

Power supplies

To supply the electrical power necessary for arc welding processes, a variety of different power
supplies can be used. The most common welding power supplies are constant current power
supplies and constant voltage power supplies. In arc welding, the length of the arc is directly
related to the voltage, and the amount of heat input is related to the current. Constant current
power supplies are most often used for manual welding processes such as gas tungsten arc
welding and shielded metal arc welding, because they maintain a relatively constant current
even as the voltage varies. This is important because in manual welding, it can be difficult to
hold the electrode perfectly steady, and as a result, the arc length and thus voltage tend to
fluctuate. Constant voltage power supplies hold the voltage constant and vary the current, and
as a result, are most often used for automated welding processes such as gas metal arc welding,
flux cored arc welding, and submerged arc welding. In these processes, arc length is kept
constant, since any fluctuation in the distance between the wire and the base material is quickly
rectified by a large change in current. For example, if the wire and the base material get too
close, the current will rapidly increase, which in turn causes the heat to increase and the tip of
the wire to melt, returning it to its original separation distance.
The type of current used plays an important role in arc welding. Consumable electrode
processes such as shielded metal arc welding and gas metal arc welding generally use direct
current, but the electrode can be charged either positively or negatively. In welding, the
positively charged anode will have a greater heat concentration, and as a result, changing the
polarity of the electrode affects weld properties. If the electrode is positively charged, the base
metal will be hotter, increasing weld penetration and welding speed. Alternatively, a negatively
charged electrode results in more shallow welds. Nonconsumable electrode processes, such as
gas tungsten arc welding, can use either type of direct current, as well as alternating current.
However, with direct current, because the electrode only creates the arc and does not provide
filler material, a positively charged electrode causes shallow welds, while a negatively charged
electrode makes deeper welds. Alternating current rapidly moves between these two, resulting
in medium-penetration welds. One disadvantage of AC, the fact that the arc must be re-ignited
after every zero crossing, has been addressed with the invention of special power units that
produce a square wave pattern instead of the normal sine wave, making rapid zero crossings
possible and minimizing the effects of the problem.

WORKING PRINCIPLE

Here our project consists of four wheels in which, the two wheels are used to transport

in normal flat lands and the one more pair of wheels to lope the whole machine to lift the things

upstairs or downstairs. There will one plate above the wheels which is used to place the

material. There will be two pillars or bars which are welded are fastened from the plate in which

the material is placed. The two wheels which are used for transportation is fixed to the base

plate of the machine. Other two wheels are also fixed with the base of the machine, but with

the lesser height than that of the other two wheels which are used for the transportation. The

upper two wheels are connected to a motor with cam mechanism to reciprocate and it will lift

the whole equipment upstairs by means of loping process. After lifting the heavy component

in the base it should be tied up such that it won’t fall, the user has to balance the handle on the

one end, and has to operate the motor clockwise while climbing up and in anticlockwise while

coming downhill. The power for the motor is from the battery which is placed.
ADVANTAGES

 Low cost

 The user can lift heavy things easily

 Move a desk without emptying drawers or clearing the top

 Easy operation, automatically locks in the raised position

 Prevents damage and slipping

 It minimizes the amount of labors or persons involved and it is a time consuming

process.

DISADVANTAGE

The person who is lifting has to balance heavy weight which is being lifted.
APPLICATION

It can be useful for packagers and movers and those who shifting houses occasionally,

especially government officers.

DRAWING FOR LOW COST HEAVY WEIGHT TRANSPORTING VEHICLE

CONCLUSION

The main conclusion will be drawn to design a transport vehicle with low cost and weight to reduce a
skilled manual process which would avoid worker fatigue. Also the future scope for developing the
generalized mechanism for any profile can be identified.

REFERENCES

[1] Work Safe victoria: “A Guide to Manual Handing in the Food Industry” info @workcover.vic.gov.au
[2] Work Cover: In this title “ Manual Handling Resources”

[3] Environment, Health, and Safety “Safe Manual Material Handling” by University Of California .

[4] Alexander Slocum “Fundamentals of Design”. 2008 Alexander Slocum5-0 1/1/2008

[5] Hazard and risks associated with manual handling in the workplace by European Agency for Safe
and health at work-http://osha.europa.eu
[6] Making the best use of lifting and handling aids by Health and Safety Executive –
www.hse.gov.uk/pubns/indg398.htm.

[7] Material Handling Solution for the Food & Pharmaceutical Industries By Clyde Material Handling
www.clydematerials.com

[8] California Department of Industrial Relations “Manual Material Handling”

[9] Work Safe Victoria “Safety by design” R. A. Gujar1, S. V. Bhaskar “Shaft Design under Fatigue
Loading By Using Modified Goodman Method”

[10]R. A. Gujar1, S. V. Bhaskar “Shaft Design under Fatigue Loading By Using Modified Goodman
Method” ISSN: 2248-9622 www.ijera.com Vol. 3, Issue 4, Jul-Aug 2013, pp.1061-1066