report

Remote Controlled Mini Forklift

Final Project Report

Submitted as partial fulfillment of the requirements for

ENGT 4050

Senior Technology Capstone

Professor Richard Springman

Project Team A-12

Abdulaziz Aljahdali (Team Leader)

Fallon Ngecha

Mohammed Alghamdi

Alaqeel Abdulrahman

Alyaqoot Abdullah

Faculty Advisor

Dr. James Kamm

December 8, 2017

The University of Toledo

College of Engineering

Engineering Technology Department

ABSTRACT

The mini forklift is built to help with easy accessibility to things around the warehouses, homes and businesses. The mechanical field is improving day by day. Lots of innovative ideas are entering in to the field. This project report is indeed to endow with a comprehensive study of the technical and theoretical aspects of “FORKLIFT” all the topics covered in this report are essential for the complete understanding and survey of the title “FORKLIFT”. In the project we have studied and modified the product called Forklift machine. The reports engross different chapter, and each is design in the organized style. Covering basic introduction, specification, application, and its uses in various industries.

WHY FORKLIFT?

· The forklifts are generally used for moving heavy goods and supplies from one place to another quickly and with less effort.

· The forklifts are small but compact machines, designed to work in tight and narrow areas.

· The best thing is that you can choose a forklift with the right configuration and capacity depending on your needs.

· One advantage of the forklifts is that they are capable to reach things located on high locations.

· Without these machines, the warehouses would not be able to operate efficiently and with easiness.

· They perform Eco-friendly operation and has Longer life

Acknowledgments:

The entire team-A-12 would like to express appreciation to all the people who helped to complete this design project. Thanks to the project’s faculty advisor, Professor

Richard Springman for helping the group in making sure that there was enough content and that the project was realistic enough and for his continuous effort to ensure better conditions for the team project activities.

Also, the authors would like to give special thanks our mentor for this project, Dr. James Kamm for his endless support and inputs which lead to the successful completion of this project. It was a great experience getting his input and him helping the team to gain some fantastic knowledge. Despite his busy schedule, he continuously guided and helped the team in providing technical expertise throughout the term, making possible the successful finalization of this senior project.

Table of Contents

Abstract………………………………………………………………………………………… ii

Acknowledgments………………………………………………………………………………. iii

Table of Contents………………………………………………………………………………... iv

List of Figures……………………………………………………………………………………. v

Introduction………………………………………………………………………………………. 1

Background and Motivation …………………………………………………………………...... 1

Project Objectives………………………………………………………………………………... 2

Project Team……………………………………………………………………………………... 3

Design and Analysis……………………………………………………………………………... 3

The Forklift Design………………………………………………………………………... 4

Results……………………………………………………………………………………………. 7

Discussion………………………………………………………………………………………. 13 Conclusion……………………………………………………………………………….………14

References………………………………………………………………………………………. 15

Appendices……………………………………………………………………………………… 16

I. Project Timeline………………………………………………………………………… 17

II. Expenses…………………………………………………………………………………19

III. Team Resumes………………………………………………………………………….. 21

IV. Detailed Component Drawings…………………………………………………………. 47

List of Figures

Figure 1: A Traditional Forklift…………………………………………………………………4

Figure 2: A Remote-Controlled Forklift…………………………………………………………. 5

Figure 3: DC motors…………………………………………………………………................... 8

Figure 4: Remote Control…………………………………………………………………........... 9

Figure 5: Forklift Tires………………………………………………………………………….. 11

Figure 6: Assembled Remote Controlled Mini Forklift………………………………………….12

List of Abbreviations (If Any)

Introduction:

        It is always great to have a bit of extra help when you need it. Forklifts are helpful tools, especially when moving bulky items around. Forklifts are primarily used in warehouses, they are expensive to own, big and in many instances difficult to operate. Wouldn’t it be great to have a mini forklift that could easily be controlled remotely? For use in warehouses or even homes and businesses. Such a device could make life easier for people with special needs, even lazy people could benefit from this. This affordable forklift could be designed and programmed to help move things easily without having to drive it. With a push of a button on the remote control, one’s items will be carried from one point to another with little effort. For the remainder of this proposal, Capstone Team A-12 will be discussing the motivation for this awesome idea and the plans to achieve certain goals.

Background and Motivation:

Forklifts are a great tool. They can be used to lift very heavy things that are beyond normal human capability. Standard commercial forklifts generally incorporate a cab, or they must be handled by man. Most forklifts are usually used to move large items which limits it for everyday uses in homes. Because of the way these already produced forklifts are built, it excludes its uses to people with disabilities such as people who are wheelchair bound.

The idea of a driverless forklift dates to 60 years old according to Len Calderone (1). The concept back then was not well developed as technology back then was not advanced as what we have today. There are other robotic forklifts out there and they are driverless. These ones are mostly used in warehouses and are usually large. These forklifts are large and take up a lot of space. As a result, it does not solve the problem of forklifts being used at homes or by disabled people. If these automated forklifts were a little small and could easily navigate in homes, offices and the like, they could have been a wider market for it which in turn would reduce the cost.

Forklifts are either powered by gasoline, propane, or electricity. Electric forklifts relay on batteries to operate. Gasoline or propane forklifts are sometimes stronger or faster than electric forklifts, but they are more difficult to maintain, and fuel can be costly. Electric forklifts are great for warehouse use because they do not give off noxious fumes like gas powered machines do.

Project Objectives:

This project is made to eliminate stigma when people hear the word Forklift. From that word, an individual could describe them as big, requires a licensed driver, probably needs a certification, warehouses and are costly. They would be correct because this is how the traditional forklifts are. The goal here is to take something that only exist mostly in warehouses and be able to introduce it to homes and businesses at a considerable cost. The process of project work depends on intelligence, skills, creativity, and energy of group of the team. The purpose of providing project work is to expose to problems and to introduce you to the procedures used to reach e efficient acceptable solution. By doing this you gain confidence in taking decision and taking problems project work will integrate and train the skill required by you in study.

Not only does this project help with dismantling the ideology behind forklift’s, it forces us as a team of students to work cordially with one another. This has made it possible for us to know how it will be working in the real jobs. This is a very mush important in engineering fields. Also, it helps the team as students to develop our minds towards engineering field and help with gaining the various knowledge of manufacturing techniques and processes. A student can develop good knowledge about various machines and equipment’s used for manufacturing of various parts which would help develop the abilities to plan for work and take appropriate decision.

Project Team:

Team-A-12 decided to do a remote controlled mini forklift project. This team consist of four mechanical engineers’ student and one information technology student from the University of Toledo. All the team members have been prepared by the University to think critically and complete calculations required to create an effective design solution. This project is a complex set of thousands of verities. The verities are in terms of technology, equipment and materials, machinery and people, work culture and ethics. But they remain interrelated and unless this is so, it is not possible to complete the project successfully.

Every member of the team was assigned to work on different parts of the project. This help with having every member of the team involved and help was provided when requested by a team member.

Design and Analysis:

For the design of this project calculations were made to determine the appropriate load to be carried and the appropriate counter weight necessary to avoid tilting. Below, listed the material selected for all parts, and the calculations used to determine the allowable load and the counter weight.

1. Materials Selected for all Parts

A. Base Plate - Mild steel Plate 0.08in thickness

B. Forklift Frame - Mild Steel Bar 1.00in x 0.16in

C. Guide Rods - Hard chrome plated rod 0.50in diameter x 12.00in Length

D. Linear bearing housing - Mild steel Block 1.00in x 0.80in x 1.40in

E. Forklift - Mild steel plate 0.08in thickness

2. Working Principle

The forklift will work on Rfid. According to the signal the forklift will travel the distance where the load is kept.

As the forklift reaches the location the forks will get down and get under the load, and when the load is over the forks and fully balanced the forks will be lifted up with the help of a motor, pulley and belt arrangement.

Now, the forklift will carry the load wherever it is needed.

As soon as it reaches its destination, the forks will get down and move back leaving the load on the ground.

3. Load Calculation

A. Total weight on the forklift = Forklift frame + forks + load + counter weight + (motor, rod, bearing, etc)

a. Forklift Frame weight = volume of frame x density of material

= (L x B x H) x (0.271 lb/in^3)

= [(1 x 0.16 x 12 x 0.08 ) + (1 x 0.16 x 7.5 x 0.08 )] x (0.271 lb/in^3)

= 0.0676416 lb.in x 1lb/0.031in

=2.2 lb

b. Forklift weight = Volume x Density of material

= (L x B x H) x (0.271 lb/in^3)

= (12 x 12 x 0.08) x (0.271 lb/in^3)

= 3.12 lb

c. Max load to be carried = 22 lb

d. Counter weight = 33 lb

e. Other materials weight (motor, guiding rod, bearing, etc.) = 11 lb approx

Therefore, total load on the bot= Forklift frame + Forklift + load + counter weight + (motor, rod, bearing, etc)

= 2.2 + 3.12 + 22 + 33 + 11

= 71.32 lb approx

Now, calculating how much load it can carry when counter weight is kept 17.63lb in static position.

Now calculating the bending moment at point B to find the load that can be carried

Bending moment formula – Mass X Distance

Bending moment at point B

BM(B) = -(A x 6) + (17.63 x 11.00)

To prevent tilting of robot the bending moment at B should be zero so,

0 = -(A x 6) + 193.93

193.93 = A x 6

Therefore, A = 193.93/6

A = 32.32 lb

Results

The results of this project are almost identical to the proposal of the project. Due to minor issues a slight increase in the budget has occurred. The completion of the project took approximately 90 days, and the final product is working efficiently and as proposed.

As of the cost of the project, the total amount that was spent on this project was $570.00, and a breakdown of all elements cost is listed in a table in the Appendices.

Discussion

This project was a success, as any project we faced minor issues that affected our proposed plan, but we had accomplished ways to overcome those issues to complete the design of the project and develop the project on time for the expo.

The device is working according to the proposed plan and has met all criteria of the design.

As an improvement of the project, a few details could change the Forklift to make it look better, such as creating a plastic cover to hide the electrical components of the device to help isolate dust, water, humidity and to keep wires out of children’s and pet’s reach.

Conclusion

Forklifts are tools which could be very helpful if they were designed in a way that could be consumed by a wide variety of people. This is the main problem with what is currently in the market. These forklifts are big and must be driven by operators that are licensed which limits it uses to millions of people. A remote controlled mini forklift is something that can change the market for forklifts. This device is designed with the use of radio frequency, it could be controlled carry what is needed by the operator. Every member of the team has contributed towards the completion of this project, by designing, preforming calculation and other duties that helped putting all parts together and making sure that the devices is working as it should.

Appendices

I. Project Time Line

II. Expenses

Part	Cost
Tires	$50.00
Driving Motors	4@$20.00
Elevating Motor	$40.00
Hardware	$39.00
Remote Control With a Receiver	$200.00
Wirings	$6.00
Electronics	$155.00
Grand Total	$570.00

III. Team Resumes

ABDULAZIZ

ALJAHDALI

2028 Orchard Lakes Pl W, Toledo, OH 43615 | (C) 419-450-0413 | [email protected]

PROFESSIONAL SUMMARY

Hardworking, enthusiastic and results-oriented Mechanical Engineer offering robust

qualifications in engineering, field management, continuous process improvements and

human relations.

EDUCATION

2014

Associate of Science: Mechanical Maintenance Engineering Technology

Jubail Industrial College, Jubail Industrial City

3.07 GPA

Coursework in Drafting, Computer-Aided Design (CAD)

Coursework includes Thermodynamics

CURRENT

Bachelor of Science: Mechanical Engineering Technology

University of Toledo, Toledo, Ohio, USA

Recipient of Saudi Arabian Ministry of Higher Educations Scholarship

3.248 GPA

Continuing education in Mechanical Engineering

Coursework in Drafting, Computer-Aided Design (CAD)

Coursework includes Thermodynamics

SKILLS

AutoCAD proficient Disciplined

Thermodynamics Quick learner

Microsoft Excel Strong decision maker

Microsoft Word Works well in diverse team environment

WORK HISTORY

JUNE 2014-SEPTEMBER 2014

Quality Control Trainee | China National Chemical Engineering | Jubail Industrial City, Saudi

Arabia

Coordinated all aspects of production, including selection of manufacturing methods,

fabrication and operation of product designs.

Performed on-site field surveys and wrote technical narratives in an efficient and timely

manner.

FALLON NGECHA

1450 COLLEGE DR. APT 10, Toledo, Ohio, 43607 * 5715984939 *[email protected]

 

Career Objective

Seeking an engineering related position with a promising, growing, stable, prestigious, high tech organization to contribute to the value of my diverse technical, business acumen and professional experience.

 

Education

Stonewall Jackson, Manassas, VA

High School Diploma, Jun 2014

 

The university of Toledo, Toledo, OH

Information Technology Candidate, Expected graduation, Dec 2017

Completed QA Training:

· Quality Assurance Testing, Defect tracking, status reporting and problem resolution within Agile & non-Agile: Waterfall and Iterative development environments to reduce operating costs and increasing efficiency.

· Software Development Life Cycle (SDLC) and well acquainted with Software Testing Life Cycle (STLC).

· Proficient in business requirement analysis, creating mockups, functional requirement document and user manual.

· Test strategy, test plan, and test cases from FRD and end user interview

· Manual Testing, Automated Testing, Smoke Testing, Integration Testing, Security Testing, 508 Compliance Testing, System Testing, UAT, And Regression.

· Regression testing strategies across multiple environments for a variety of business applications.

· Coordinating and communicating with various teams and stakeholders involved in the project

· Reporting and prioritizing software bugs in conjunction with the Development & QA Managers and analyzing the Test Results.

· SQL queries to view successful transactions of data and for validating data.

Work Experience

The University of Toledo, Toledo, OH

Computer Lab Assistant, Sep 2014 - Present

· Assist students to locate and utilize class materials in lab computers

· Help professors with finding, setting up and playing videos for their class

· Keep work environment clean in accordance to the university rules

· Train new employees as AUT end user history

· Troubleshoot printer issues to make sure they are up to date and working for students and professors using the lab

 

Andy Frain Services, Perrysburg, OH

Security Officer, Jan 2017 – Nov. 2017

· Check FedEx ground workers personal belongings before letting them in to the facility

· Wand workers entering and exiting the unit for any weapons or stolen packages

· Login and count trucks entering or exiting the facility

· Do property check on the enter facility to make sure that everything is fine

· Help customers with package issues by connecting them to the right FedEx ground center

 

Velocity-greatest phone company

IT CALL TECHNICIAN, May 2017 – August 2017

· Provide accurate and timely notes of all procedures performed while attempting to resolve the issue, updating tickets frequently with these notes.

· Analyze problems with equipment in a very rapid manner to determine cause of the issue with the most accurate diagnosis as possible.

· Correctly escalate tickets to appropriate team(s) to resolve issue in the most rapid manner possible.

· Direct the onsite Tech to perform a very professional installation of our products and services at the customer locations.

· Ensure all configurations are tested and working as intended and needs of the customer before leaving site.

· Ensure that ticketing system is updated properly with proper notes.

· Maintenance and troubleshooting repairs:

· Perform other duties as assigned

class projects

· Came up with new and efficient way for the university to use solar panels for power supply for the campus.

· Designing web pages

· Web security

 

School Organizations

· AITP: Association of Information Technology Professionals

· APA: African Peoples Association

 

References

· Justin Gale (Supervisor): 4193460798

· Rajesh Nagisetty (Supervisor): 4195373658

Abdulrahman Alaqeel

1516 Cherry Valley Road, Toledo. OH. 43607

(567)-377-7906

[email protected]

OBJECTIVE
· To obtain a cooperative education position in the Mechanical Engineering Technology field that will help me to know more and use my skills in my major.
EDUCATION
August 2013- Present	The University of Toledo Toledo, Ohio · Bachelor of Science in Mechanical Engineering Technology · Anticipated Graduation Date: Dec 2017 · Current Grade Point Average: 3.16/4
TRAINING AND CERTIFICATIONS
Feb 2015 Apr 2014	· Lean Six Sigma Greenbelt. (24 Hours). · OSHA General Industry Safety Training. (10 Hours).
SKILLS
Programming and Software: Languages:	· AutoCAD, Minitab, SOLIDWORKS, and Microsoft Office. · English and Arabic.
COLLEGIATE ACTIVITIES
Dec 2015	· Active member of the Saudi student association at the University of Toledo.

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