Mechanical Climbing Wheelchair

DESIGN AND FABRICATION OF STAIRCASE CLIMBING WHEELCHAIR
INTERNSHIP PROJECT REPORT
Submitted by
NITISH KUMAR JANMEJAY JAISWAL
IN
AEROSPACE ENGINEERING
INDIAN INSTITUTE OF SPACE SCIENCE AND TECHNOLOGY THIRUVANANTHAPURAM

July 2011
BONAFIDE CERTIFICATE
This is to certify that this project report entitled DESIGN AND FABRICATION OF STAIRCASE CLIMBING WHEELCHAIR submitted to Indian Institute of Space Science and Technology, Thiruvananthapuram, in connection with the institute internship program is a bonafide record of work done by Nitish Kumar and Janmejay Jaiswal under my supervision at the Indian Institute of Space Science and Technology from 27th June 2011 to 5thAugust 2011
Dr. K. Kurien Issac Senior Professor and Head, Department of Aerospace Engineering Indian Institute of Space Science and Technology
Place: Thiruvananthapuram Date: 8th August, 2011
IIST Thiruvananthapuram
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Table of Contents
ACKNOWLEDGEMENT _______________________________________________ v ABSTRACT ___________________________________________________________ vi LIST OF FIGURES ___________________________________________________ vii LIST OF TABLES _____________________________________________________ ix Chapter 1 Introduction and Objectives ____________________________________ 1 Chapter 2 Working of mechanism ________________________________________ 2 Chapter 3 Detailed Design of Mechanism __________________________________ 6 3.1 Design of Slider _________________________________________________________ 6 3.1.1 Strip 1 ______________________________________________________________ 6 3.1.2 Strip 2 ______________________________________________________________ 7 3.1.3 Spacer ______________________________________________________________ 8 3.1.4 Steel Ball____________________________________________________________ 8 3.2 Design of link of four bar mechanism _______________________________________ 9 3.2.1 Drawing of link of 4 bar mechanism ______________________________________ 9 3.2.2 Drawing of connecting rod of 4 bar mechanism ____________________________ 10 3.3 Specification of gear ____________________________________________________ 10 3.4 Specification of Lever arm _______________________________________________ 11 Chapter 4 Fabrication of Slider __________________________________________ 12 Chapter 5 Experiment _________________________________________________ 14 Chapter 6 Conclusion & Recommendation ________________________________ 16 References ___________________________________________________________ 18 APPENDIX __________________________________________________________ 19 1. 2. Drawing of Outer Plate _________________________________________________ 19 Drawing of Intermediate plate ___________________________________________ 20
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3. 4. 5. 6. 7. 8. 9.
Drawing of Inner plate _________________________________________________ 21 Drawing of slot connected to intermediate plate _____________________________ 22 Drawing of slot connected to Inner plate ___________________________________ 23 Drawing of strip1 of slider ______________________________________________ 24 Drawing of strip2 of slider ______________________________________________ 25 Solid Model of Stair climbing Mechanism__________________________________ 26 Complete Solid Model of Stair climbing Wheelchair _________________________ 28
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ACKNOWLEDGEMENT
The completion of this project and this report owes itself to the invaluable help and support of Dr. K. Kurien Issac, Senior professor and Head, Department of Aerospace Engineering, Indian Institute of Space Science and Technology. We would also like to express our gratitude towards Mr. Thomas Varghese, Manufacturing lab in-charge, Indian Institute of Space Science and Technology, for his assistance in fabrication and other valuable inputs.
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ABSTRACT
In this project, we aim at designing and fabricating the entire mechanism. The basic working of mechanism is explained. We made a detailed design of mechanism for climbing wheelchair. Solid model of entire mechanism is also made. We also fabricated slider part of mechanism. Finally all the fabricated parts of slider is assembled.
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LIST OF FIGURES
Figure 1: Isometric view of mechanism of staircase climbing wheelchair Figure 2: Initial configuration Figure 3: Descending of wheelchair Figure 4: Sliding up the outer column Figure 5: Rising of wheelchair Figure 6: Sliding up of wheelchair Figure 7: Top view of Strip 1 Figure 8: Front view of Strip 1 Figure 9: Top view of Strip 2 Figure 10: Front view of Strip 2 Figure 11: Cross sectional view of assembled slider Figure 12: Link of mechanism Figure 13: Connecting link of mechanism Figure 14: Top view of fabricated Strip 1 Figure 15: Top view of fabricated Strip 2 Figure 16: Front view of fabricated slider Figure 17: Top view of fabricated slider Figure 18: Skeleton view of Slider Figure 19: Sine bar along with slip gages (gauge blocks) Figure 20: Sine Table
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Figure 21: Isometric view of I-shape slider Figure 22: Front view of stair climbing Mechanism Figure 23: Top view of stair climbing Mechanism Figure 24: Side view of stair climbing Mechanism Figure 25: Isometric view of stair climbing Mechanism Figure 26: Isometric view of stair climbing Wheelchair Figure 27: Front view of stair climbing Wheelchair Figure 28: Top view of stair climbing Wheelchair Figure 29: Side view of stair climbing Wheelchair
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LIST OF TABLES
Table 1: Specification of Lever arm Table 2: Specification of gear Table 3: Value of between different surfaces
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Chapter 1 Introduction and Objectives

The invention of wheelchair has given independence to many people who would normally have been totally dependent on other. However problem with wheelchair comes when people have to go through stairs. In order to address this problem, many people have made mechanism of different design to climb wheelchair along stairs. One of the designs is patented by G.H.Green. His wheelchair uses ingenious mechanism to climb by making two arms move along a trajectory similar to that of a foot. This includes complex mechanism driven by motor. This mechanism is simplified by Supratim Naskar in his B. Tech. project at IIST in 2011. The aim of our project is to make a detailed design of this simplified mechanism of staircase climbing wheelchair and fabrication of its parts. This includes fabrication of different parts of mechanism which would be done in manufacturing lab, modifying some of the existing design. The solid modeling of different parts of mechanism would be made using CAD software.
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Chapter 2 Working of mechanism

The figure below shows how this mechanism is designed to make the wheelchair climb up a staircase.
Lever arm 2
Gear 1
Gear 2
Lever arm 1
Protrusion
Outer slider column Platform for wheel chair Inner column
Vertical Prismatic joint
Intermediate column
Figure 1: Isometric view of mechanism of staircase climbing wheelchair
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Figure 2: Initial configuration Figure 2 shows the initial configuration. Now, lever arm 2 is pulled down. This descends the wheelchair on the staircase. The inner plate can easily move vertically down along the vertical prismatic joint between the intermediate plate and the inner plate. The wheelchair is attached to the inner plate directly, hence as the inner plate moves down the wheelchair also moves down. When the chair has completely moved down, lever arm 2 is locked at that position so that the chair is locked in this position. In this configuration (fig. 3), the inner column is on the staircase and is supporting the entire weight of the system.
Figure 3: Descending of wheelchair IIST Thiruvananthapuram

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Now when the wheelchair is locked in this position, outer column can only slide along the slope of the staircase through the intermediate column. As lever arm 1 is pushed backward, gear 1 rotates in anti-clockwise direction, forcing gear 2 to rotate in a clockwise direction. The link connecting gear 2 and the slider (outer) column is fixed with gear 2 and is pivoted at the center of gear 2. So as gear 2 rotates clockwise, the link also rotates clockwise and this causes slider column to slide up along the intermediate column. When the slider column has moved along the slope of the staircase, lever arm 1 is locked at that position and the slider column stays there as shown in fig.4.
Figure 4: Sliding up the outer column We unlock lever arm 2 and push it up. This raises the wheelchair from the staircase. The raising happens as the bearings forces the protrusions on the inner plate to move up. When the chair has completely moved up, lever arm 2 is locked at that position so that the chair is locked in that elevated position. In this configuration the slider column is on the staircase and is supporting the entire weight of the system (fig.5).
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Figure 5: Rising of wheelchair Now when the wheelchair is locked in the lifted position, it can only slide along the slope of the staircase through the slider column. As lever arm 1 is pushed forward, gear 1 rotates in a clockwise direction, forcing gear 2 to rotate in an anti-clockwise direction. Due to this, the link also tries to rotate anti-clockwise but the slider column on the other end of the link is supported on the stairs and cannot move. This provides a reaction force on the shaft of gear 2. This causes the chair to slide up along the slider column and the initial configuration is restored as shown in fig.6.
Figure 6: Sliding up of wheelchair IIST Thiruvananthapuram

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Chapter 3 Detailed Design of Mechanism

Design of different parts of mechanism like outer plate, intermediate plate, inner plate, slot connected to intermediate and inner plate and links of four bar mechanism are included in the Appendix section. In this chapter, we give the design of slider which has to be fabricated.
3.1 Design of Slider

Slider is designed using Steel balls and Aluminium strips. Steel balls are kept on 3.5mm thick Aluminium strip (strip 1) by making a tapered hole. In order to make ball rotate in its place, thin Aluminium strip of 1.5mm strip (strip 2) is used as a cage.
3.1.1 Strip 1
Design of strip 1 is shown below.
Figure 7: Top view of Strip 1
Figure 8: Front view of Strip 1
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As shown in above figure, Steel ball of 6mm diameter is kept on tapered hole of strip 1. Taper angle of hole is 45 . Also, through hole of 3mm diameter is made at equal interval to fix strips 1 & 2 using countersunk bolt M3x6.
3.1.2 Strip 2
Strip 2 acts as a cage to keep the ball in tapered hole. Its drawing is shown below.
Figure 9: Top view of Strip 2
CSK bolt hole
Stell ball hole
Figure 10: Front view of Strip 2
Since we are using countersunk bolt, tapered hole is made to fit the bolt. Another inverted tapered hole is made so that upper face of ball will come out of hole.
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3.1.3 Spacer
To prevent the contact of ball with strip 2, we use nylon spacer of 1.7mm thickness. If spacer is not used, ball would be in contact with both the plates and pure rolling of ball would not be possible.
3.1.4 Steel Ball
Steel balls are placed on 45 chamfer, so that it makes only point contact in 2D which makes it to roll when chair slides over the slider. The idea behind placing balls at 45 chamfer is to convert the sliding friction into rolling friction, when tangential force is applied which makes it to roll in its place and hence reduce the friction.
Stell ball
Strip 2
Spacer
Strip 1
Figure 11: Cross sectional view of assembled slider
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3.2 Design of link of four bar mechanism

It has been observed during designing process that as four bar mechanism is moving, connecting link was obstructing with prismatic joint. To avoid it, we design connecting link of C-shaped.
3.2.1 Drawing of link of 4 bar mechanism
Figure 12: Link of mechanism
In this link, one end is connected using Mx10 nut and bolt to the intermediate plate while other end is connected to connecting link of four bar mechanism.
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3.2.2 Drawing of connecting rod of 4 bar mechanism
Figure 13: Connecting link of mechanism
This connecting link is connected to link shown in section 4.2.2.
3.3 Specification of gear
Module Diametrical Pitch Nominal face Width Diameter of gears Pressure angle Teeth Depth Table 1
2 12 25mm 100mm 20 10mm
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3.4 Specification of Lever arm

We use two lever arms 1 and 2 for horizontal and vertical movement respectively. Lever arm 1 2 Table 2 Length (mm) 600 900
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Chapter 4 Fabrication of Slider
Strip 1 of slider of 6082 T6 grade Aluminium of size 40mm x 3mm cross section and 1000mm length was available. Since we required 35.6mm x 3mm cross section, vertical milling operation is used to reduce width of Aluminium flat bar from 40mm to 35.6mm. Due to non-availability of 35mm x 2mm cross section Aluminium flat bar, Aluminium L-bar of 35mm width on both sides and 2mm thickness is obtained. From this L-bar, we obtained 35mm x 2mm cross section strip 2 flat bar by cutting L-bar using hex saw. Steps involved in making slider Using Height gage, marking on strip 1 is done at equal interval where hole is to be made as shown in fig.7. Then using C-clamp, we clamp both the strips at three points along the length. First, we drill through hole of diameter of 2mm at the marked points, where steel ball would be kept, through the entire length of clamped strips. Through holes of diameter 2.5mm is drilled at the marked points where countersunk bolts would be fitted. Since standard drill bit have 118 tool angle, we grind it to obtain 90 tool angle. Now we chamfer the ball hole using 6.5mm drill bit with 90 tool angle on strip 1 as shown in fig.8. Tapping of all 2.5mm diameter holes in strip 1 is done using M3 tap manually.
Figure 14: Top view of fabricated Strip 1 IIST Thiruvananthapuram
Figure 15: Top view of fabricated Strip 2

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Using same 6.5mm drill bit, we chamfer CSK bolt hole in strip 2 as shown in fig.9. We also chamfer ball hole in strip 2 using 8mm drill bit with 90 tool angle. To make 1.7mm thick and 10mm diameter spacer having 3mm hole at center, we use Nylon rod of 50cm length and 10 mm diameter. Then using turning process in lathe we drill hole of 3mm diameter through the center of Nylon rod. Again using turning process we cut 1.7mm thick spacer from rod. Assembly of the parts of slider is done
Figure 16: Front view of fabricated slider
Figure 17: Top view of fabricated slider
Figure 18: Skeleton view of Slider
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Chapter 5 Experiment
In order to know how much advantage slider giver over without slider, we found experimentally the coefficient of friction () between slider and Aluminium strip & coefficient of friction () between two Aluminium strips. Experiment To find , we use Sine table and slip gages are used to measure height as shown in figure. Now on the Sine table, slider is clamped and it is kept at some angle using slip gages. Aluminium strip is kept on inclined slider such that it doesnt slide over slider. Now height h is increased by 1mm in steps using slip gages until Aluminium strip starts moving on the slider. At this height, height h is measured. Since the distance between centers of ground cylinder of sine table l is 150mm, inclined angle (also called angle of repose) is found using
=arcsine ( )
Figure 19: Sine bar along with slip gages (gauge blocks)
Figure 20: Sine Table
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Same procedure is repeated by clamping Aluminium strip on sine table and keeping another Aluminium strip on it. Now we can find coefficient of friction using
=tan
Observation Metal Pair Slider-Aluminium Strip Aluminium-Aluminium Strip Height h(mm) 29.5 41 (degree) 11.34 15.86 0.2 0.284
Table 3: Value of between different surfaces Result From the above experiment, it is observed that coefficient of friction is decreased by 0.084 by using slider in mechanism.
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Chapter 6 Conclusion & Recommendation

The solid model of mechanism is successfully done to meet the objective of project. We have also fabricated the slider. Due to time constraint, all the parts of mechanism could not be fabricated. But now since the detailed design is made, other parts of mechanism can be made. After designing and fabricating the slider, we observed following drawbacks. The material we have used to make slider is aluminum which is much softer then steel balls, due to which when large load is applied on the slider, chamfer on which steel ball is kept will be deformed and it will form shape in which the ball will just fit which will cause jamming and hence friction will increases. Also for drilling holes on strip, machine does not have long bed which causes some part of strip to hang out of the bed. This also causes mismatch during assembly of different part of slider. In course of using the slider, wear and tear will we more which causes increase in friction. Following are remedy to overcome above problem. Material used must be harder than steel ball which will decrease friction and reduce wear and tear. We could have used mild steel instead of Aluminium in slider but then machining of mild steel would be difficult and caused lots of vibration. This would create dimension mismatch between two strips of slider. For machining, long bed must be used and work piece must be tightly clamped and sharp tool must be used and burrs should be removed manually. Improvement in design Design can be improved by using ball bearing instead of slider by making I-shaped slider and place ball bearing at the ends of I and place this structure in the track which ensures the free rotation of ball bearing and also provide the track for the movement of chair. This design will reduce manufacturing cost significantly and also reduces the friction drastically and hence less effort will we required for movement.
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Ball Bearing
Figure 21: Isometric view of I shape slider
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References
[1] John J. Uicker, Gordon R. Pennock ,Joseph E. Shigley, Theory of Machines and Mechanisms, Oxford University Press, New Delhi,2009 [2] http://www.catia.com.pl/ [3] Supratim Naskar, Design of a wheelchair capable of climbing staircases using only user effort, IIST, 2011
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APPENDIX
1. Drawing of Outer Plate
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2. Drawing of Intermediate plate
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3. Drawing of Inner plate
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4. Drawing of slot connected to intermediate plate
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5. Drawing of slot connected to Inner plate
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6. Drawing of strip1 of slider
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7. Drawing of strip2 of slider
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8. Solid Model of Stair climbing Mechanism
Figure 22: Front view
Figure 23: Top view
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Figure 24: Side view
Figure 25: Isometric view
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9. Complete Solid Model of Stair climbing Wheelchair
Figure 26: Isometric view
Figure 27: Front view IIST Thiruvananthapuram

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Figure 28: Top view
Figure 29: Side view IIST Thiruvananthapuram

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DESIGN AND FABRICATION OF STAIRCASE CLIMBING WHEELCHAIR

INTERNSHIP PROJECT REPORT

NITISH KUMAR JANMEJAY JAISWAL

INDIAN INSTITUTE OF SPACE SCIENCE AND TECHNOLOGY THIRUVANANTHAPURAM

Place: Thiruvananthapuram Date: 8th August, 2011

Chapter 1 Introduction and Objectives

Chapter 2 Working of mechanism

Outer slider column Platform for wheel chair Inner column

Vertical Prismatic joint

Figure 1: Isometric view of mechanism of staircase climbing wheelchair

Figure 3: Descending of wheelchair IIST Thiruvananthapuram

Figure 6: Sliding up of wheelchair IIST Thiruvananthapuram

Chapter 3 Detailed Design of Mechanism

3.1 Design of Slider

Design of strip 1 is shown below.

Figure 7: Top view of Strip 1

Figure 8: Front view of Strip 1

Figure 9: Top view of Strip 2

CSK bolt hole

Stell ball hole

Figure 10: Front view of Strip 2

Figure 11: Cross sectional view of assembled slider

3.2 Design of link of four bar mechanism

Figure 12: Link of mechanism

3.2.2 Drawing of connecting rod of 4 bar mechanism

Figure 13: Connecting link of mechanism

This connecting link is connected to link shown in section 4.2.2.

3.3 Specification of gear

2 12 25mm 100mm 20 10mm

3.4 Specification of Lever arm

Chapter 4 Fabrication of Slider

Figure 14: Top view of fabricated Strip 1 IIST Thiruvananthapuram

Figure 15: Top view of fabricated Strip 2

Figure 16: Front view of fabricated slider

Figure 17: Top view of fabricated slider

Figure 18: Skeleton view of Slider

Figure 20: Sine Table

Chapter 6 Conclusion & Recommendation

Figure 21: Isometric view of I shape slider

2. Drawing of Intermediate plate

3. Drawing of Inner plate

4. Drawing of slot connected to intermediate plate

5. Drawing of slot connected to Inner plate

6. Drawing of strip1 of slider

7. Drawing of strip2 of slider

8. Solid Model of Stair climbing Mechanism

Figure 22: Front view

Figure 23: Top view

Figure 24: Side view

Figure 25: Isometric view

9. Complete Solid Model of Stair climbing Wheelchair

Figure 26: Isometric view

Figure 27: Front view IIST Thiruvananthapuram

Figure 28: Top view

Figure 29: Side view IIST Thiruvananthapuram

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