Design of Advanced Loading Cycle Rickshaw Rasika S

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International Journal of Innovative and Emerging Research in Engineering Volume 3, Issue 10, 2016 Available online at www.ijiere.com International Journal of Innovative and Emerging Research in Engineering e-ISSN: 2394 – 3343 p-ISSN: 2394 – 5494

Design of Advanced Loading Cycle Rickshaw Rasika S. Khairkar a a PRMIT & R Badnera, Amravati, Maharashtra, India

ABSTRACT: The present paper is to design and development of loading cycle rickshaw. It includes the self weight of cycle rickshaw is reduced by replacing some heavier material with lighter one, the torque is nearly doubled by using gear train of torque multiplier mechanism and the unloading is done by tilting the rickshaw carriage about pivots provided on the frame. The purpose of this paper is to reduce the effort of the rickshaw puller and to have quick unloading mechanism of goods. This paper will lead to a safe, easy and comfortable mode of transport in three wheeled non-engine cargo. This is the long lasting mode of transport since it is not affected by fuel crisis and the green mode of transport thus will greatly reduce the pollution. Keywords: Loading cycle rickshaw, torque multiplier, load, unload, mechanism, aluminum sheet

I. INTRODUCTION A cycle rickshaws are widely used for transportation throughout the India. The basic rickshaw is a three-wheeled tricycle design, pedalled by a human driver in the front and with a bench seat in the rear for conveying goods and luggage. There are an estimated eight million cycle rickshaw pullers in India alone, with many more in Bangladesh and other developing countries[1]. But cycle rickshaws are growing in popularity even in developed countries. With ‘Pedicab’ services springing up in major cities as an environment friendly method of transportation for goods and luggage. In India, Rickshaws are one of the most important means of transportation. However, rickshaws frequently serve as a means of employment for poor rural citizens who have migrated to the cities looking for work. In the past years, the changes that took place in the design of the vehicle have not been very prominent. Bicycle rickshaws impose significant physical burden on the drivers[2]. Used throughout India for transportation these rickshaws are not designed for driver comfort and safety[3]. Instead, traditional rickshaws are only single speed, with an extremely high gear ratio that makes it difficult for drivers to pedal with large loads. Particularly in India, many rickshaw drivers are under-nourished and the physical exertion to pedal loads over rough roads and uneven terrain leads to severe health consequences[4]. Also the design of existing rickshaw does not facilitate the loading and unloading of goods from the carrier. The method available for loading and unloading is very tedious and unsafe which creates severe back problem. Despite this, the cost and other constraints on modifications to the rickshaw limit, which solutions are feasible. Objectives:

1. To perform the literature review 2. To reduce the effort of the rickshaw puller by employing a proper gearing system there by increasing the effective torque 3. To change the material of rickshaw to reduce its self-weight 4. To facilitate proper loading and unloading method for the ease of carrying goods

II. LITERATURE REVIEW A. History of Rickshaw The word “rickshaw”was originated in Asia where it was mainly used as a means of transportation for the social elite. Rickshaws are a mode of human-power transport and it was first seen in Japan around 1868. Rickshaw is derived from the Japanese word ‘jinricksha’[5], which means hand drawn cart. Apparently in early 20’s a Jesuit priest in India put a cycle wheel pedals in front of the original rickshaw and this are the design which has been used since then. The gearing and the mechanical advantage of the pedal was very poor. The braking system was also very poor with only front brakes on the rickshaw. A cycle rickshaw also known by a variety of other names such as pedicab, bike taxi, velotaxi, bikecab, cyclo, beca, becak, trisikad or trishaw. The cycle rickshaw is used for transportation of passengers. A rickshaw used for transportation of goods, luggage and raw materials is called as ‘loading rickshaw’. There are various types of cycle rickshaw such as pedicab, loading cycle rickshaw, electric- assist rickshaw, soleckshaw etc[6][7][8]. 9

International Journal of Innovative and Emerging Research in Engineering Volume 3, Issue 10, 2016 B. Field Survey / Observation Observations were made on how an elderly would climb up and down from the rickshaw. Since the footboard of the rickshaw is too high, it creates problem to climb. There is no option for variable speeds for uphill, downhill, straight flat roads. There is no proper braking system. Also any alternate source of power is not available. Comfort level is also poor in the traditional type of rickshaw.

III. SYSTEM DEVELOPMENT The system development is carried out in three phases as and according to the problems are as follows Phase 1: To reduce self-weight of cycle ricks The phase one consists of solving the problem of self-weight of the rickshaw. The classical cargo rickshaw consists of heavy wooden plates. These plates weighs 15 to 20 Kg also these plates absorb moisture which is enough to increase the weight considerably. Also the problem of roughness of the wooden planks or plates is a vicious one. Normally the wooden plates cost 500 INR approximately with no fixed rate per plate. Also there are no standard parameters of size and shape available for the wooden plates. Therefore suggest important solution for this problem viz. employing the aluminum sheet. The aluminum sheet and its alloys have quite a huge upper-hand over the carbon fiber sheet and the wooden planks. Not only aluminum sheets are light in weight but have very good properties of toughness and strength. Also when compared to cost estimation aluminum sheet is cheaper than carbon fibers and other types of sheet. Whereas it costs just a little over ₹200 more over same size of wooden planks but has greater weight reduction characteristic than same size of wooden plank or sheet. Aluminum sheet is defined as cold-rolled material over 0.2mm thick but not exceeding 6mm thick.

Photo 1: Section of Aluminum Sheet

A. Design of Aluminium sheet for cycle rickshaw

The Aluminum checker plate can be employed at the carriage which is lighter than wooden plates. The design consists of selection of proper aluminum sheet of appropriate size. The sheet should have sufficient tensile and compressive strength since it is subjected to cyclic loading. It should be also tough enough to have good resistance against the sudden shocks.

Dimensions of Aluminum sheet:

Length =1112 mm Width= 718mm Thickness= 2mm

B. Modelling of Rickshaw Carriage with AL Sheet Using CATIA V5 R20:

a. Carriage The Carriage is used to carry the goods. It’s the most important link in the weight reduction mechanism as the aluminumsheet rests on the trolley or carriage. The trolley is designed in CATIA as per the specifications required viz. 1112*718*2mm. The accurate dimensioning is very necessary for the proper aluminum sheet fixture.

International Journal of Innovative and Emerging Research in Engineering Volume 3, Issue 10, 2016

Photo 2: Carriage b. Carriage and Sheet Assembly The aluminum sheet having its thickness 3mm is bolted on to the carriage with the help of screws. The aluminum sheet assist in self-weight reduction as well as friction less movement of goods over it.

Photo 3: Carriage and Sheet Assembly Phase 2: To reduce the effort of rickshaw puller The phase two consists of solving the problem of efforts required by the rickshaw puller when an additional load is mounted more than the conventional load of 200Kg to 250Kg.The solution was sought out to this problem after a lot of research and analysis viz. by employing gear train with suitable gear reduction mechanism. Sometimes, two or more gears are made to mesh with each other to transmit power from one shaft to another. Such a combination is called gear train or train of toothed wheels. The nature of the train used depends upon the velocity ratio required and the relative position of the axes of shafts. A gear train may consist of spur, bevel or spiral gears[9]. Employing a gear train is a quite convenient and effective method of effort reduction. This method is employed due to availability of gears of various pitch and teeth so as to obtain greater effort reduction due to greater increased torque. The mechanism works on the principle that when angular speed of the gear is reduced, increase in torque is obtained. We employed a dual gear reduction mechanism. In this mechanism we make the application of dog clutch of a bike which would enable the engagement and disengagement of gears. This dog clutch is operated by means of a lever extending from dog clutch to below the seat of the rickshaw puller which is hand operated. Also make the use of intermediate shafts to mount the dog clutch as well as free wheel. Thus the above principle is the basis of the effort reduction process.

A. Modelling of Various Elements and Parts of Torque Multiplier Mechanism Using CATIA V5 R20: a. Dog Clutch:

Dog clutch is a gear assembly which has a dog between two gears. It mesh with either of two gears by sliding over spleens of shaft. It has shaft of diameter 20mm, gear A of diameter 80mm and diameter B of 75mm diameter.

International Journal of Innovative and Emerging Research in Engineering Volume 3, Issue 10, 2016

Photo 4: Dog Clutch b. Gear Selector

This mechanism is used to select the proper gear with the requirement of torque. It provides the sliding motion to the dog to change the gear.

Photo 5: Gear Selector c. Intermediate Shaft

It is a shaft which has a gear of 28 teeth and is mesh with the gear B, on the gear B a sprocket of 24 teeth is welded to facilitate to deliver power to the rear axle via chain and sprocket drive system.

Photo 6: Intermediate Shaft d. Assembly of components

International Journal of Innovative and Emerging Research in Engineering Volume 3, Issue 10, 2016 The assembly of components consists of the various gears, sprockets, chains, shafts, nuts and bolts etc. They are assembled to obtain the complete mechanism of effort reduction as well as for the normal operation of cycle rickshaw.

Photo 7: Assembly of components

Phase 3: To provide the quick unloading mechanism The phase three consists of solving the problem of loading and unloading of goods. The classical cargo rickshaw includes overturning of the complete rickshaw to unload the goods or the puller has to lift the load or sacks on his shoulder against the friction of the wooden planks. To overcome this issue we induced the toggle jack mechanism which ensures easy lifting of the rickshaw trolley. The mechanism consists of a toggle jack which is mounted just below the center of gravity of the trolley. Arrangements are made to hinge the trolley at the rear side above the wheels while the front side of the trolley will be free. Whenever the lever of the toggle jack is rotated, the toggle jack becomes operational and the trolley is lifted which assists in the removal of the loads. When the toggle jack is unlevered the trolley rests in its original position.[10][11][12]

A. Design of unloading mechanism

Center of gravity is the point of a body at which all the mass of the body may be assumed to be concentrated. The force of gravity acts vertically downwards from this point with a force equal to the weight of the body. Basically the body would balance around this point. The COG of a homogeneous body is at its geometrical center. B. Effect of removing or discharging mass

Photo 8: Position of Centre of Gravity

Consider a rectangular plank as shown. The effects of adding or removing weights would be as shown. Now cut the length of plank of mass ‘w’ kg whose CG is ‘d’ meters away from CG of the plank.

International Journal of Innovative and Emerging Research in Engineering Volume 3, Issue 10, 2016 Note that a resultant moment of ‘w x d’ kg m has been created in an anti-clockwise direction about ‘G’. The CG of the new plank shifts from ‘G’ to ‘G1’.

L sinθ Change in CG= tan (90−휃)

C. Modelling of Various Elements and Parts of Unloading Mechanism Using Catia V5 R20 a. Carriage Pivots

The carriage pivots assist in proper lifting of the trolley at an angle of about 50 to 60 degrees. One end of the trolley is fixed to the carriage pivots about which trolley is tilted.

Photo 9: Carriage Pivots

b. Tilted Carriage

The carriage trolley mounted on carriage pivots assists in the loading and unloading of goods and is the key to this mechanism

WITH Photo 10: Tilted Carriage

IV. WORKING The working mechanism of torque multiplier, it has two modes of operations. A. WITH NORMAL GEAR RATIO OF 48*24  The power is developed by paddling the rickshaw in the front sprocket (48 teeth)  This power is transmitted to the dog clutch shaft by free wheel F1(24 teeth) via chain drive and torque delivered is (T)  As the dog clutch shaft and dog rotates, it transmit the power to the gear A which is engaged with dog  It transmit the power to the free wheel F2 welded to it  This free wheel F2 transmit the power to the free wheel F3  As F3 rotates, it rotates the rear axle and thereby wheels with normal gear ratio of 48*24 with torque (T)  Thus in first position of the gear selector lever normal drive is obtained with same torque (T)

International Journal of Innovative and Emerging Research in Engineering Volume 3, Issue 10, 2016 B. GEAR RATIO OF 48* 56  The power is developed by paddling the rickshaw in the front sprocket (48 teeth)  This power is transmitted to the dog clutch shaft by free wheel F1(24 teeth) via chain drive with toque (T)  As the dog clutch shaft and dog rotates, it transmit the power to the gear B(18 teeth) which is engaged with dog  Gear B transmit the power to the intermediate shaft via gear C(29 teeth) and torque is multiplied by factor 1.61(1.61 T)  A free wheel F4 (18 teeth) is welded to the gear C and rotates about intermediate shaft and has torque of (1.61 T)  Free wheel F4(18 teeth) transmit the power to free wheel F5(24 teeth) and torque is multiplied by factor 1.333 and becomes 2.21(2.21T)  Thus in second position of the gear selector lever drive double torque (i.e.2.21) is obtained

V. PERFORMANCE ANALYSIS Performance analysis consists of comparison of performance of existing rickshaw and the proposed cycle rickshaw. A. Comparison of ordinary cycle rickshaw and proposed cycle rickshaw Table 1: Comparison of ordinary and proposed cycle rickshaw Sr. No Parameters Ordinary Cycle Rickshaw Proposed Cycle Rickshaw 1 Gross weight 80 Kg 70 Kg 2 Capacity 500 Kg 800 Kg 3 Life of Carriage 3 Years Up to 10 Years 4 Torque at Wheels Required Available Required Available 1) No Load 15.40N-m 23.6 N-m 15.40N-m 51 N-m 2) 350 Kg 36.31 N-m 23.26 N-m 36.31 N-m 51 N-m 3) 500 Kg 43.83 N-m 23.26 N-m 43.83 N-m 51 N-m 4) 700 Kg 50.83 N-m 23.26 N-m 50.83 N-m 51 N-m 5 Torque Multiplication Factor T 2.21 T 6 Gear Ratio 48*24 48*56 7 Unloading time 10-15 minutes 106 Seconds 8 Cost INR 8200/- 11,650/- 9 Speed N N/2

VI. CONCLUSION  The gross weight of rickshaw is reduced by 10 Kg  The new formed carriage i.e. carriage with aluminium sheet has higher strength than conventional carriage. Conventional carriage is generally designed for 600 Kg to 700 Kg. whereas carriage with aluminium sheet can handle the weight up to the 1000 Kg safely.  The torque available at wheels is doubled (2.21T) that of ordinary rickshaw  Based on the testing and results, it is safe to use Toggle Jack under certain specifications. Furthermore the torque supplied on the system is enough to lift a carriage to desire height to easily unload the material.

REFERENCES [1] Pradhan CK, Thakur S, Mukherjee AK and Roychowdhury et al, “Energy expenditure of cycle rickshaw pullers in different places in India. Ergonomics 2008, 51: 1407-1417. [2] ROHC. Evaluation of Occupational Health Problems ofCycle Rickshaw pullers and Re-design of Cycle Rickshawon Ergonomic Principles. Kolkata: Regional OccupationalHealth Centre, 2009. [3] ACCC (Australian Competition and Consumer Commission). 2007. Department of Health and ageing ‘Safety Alert working under a vehicle’. 2007 Brochure. [4] Pradhan CK, Thakur S, Mukherjee AK and Roychowdhury A. Physiological assessment of cycle rickshaw pullers. Ind J Physiol & Allied Sci, 2004, 58:113-118. 15

International Journal of Innovative and Emerging Research in Engineering Volume 3, Issue 10, 2016

[5] http:// en.wikipedia,org/wiki/Japanese-jinriksha, [Accessed on 12 January 2014] [6] http:/ / www. cyclepublishing.com/cyclingbooks/dc. Html, [Accessed on 2 December 2013] [7] Heizer, J. and Render, B. 2006. “Battery-powered Soleckshaw”, Pearson International Edition. [8] Les Forcats de la Route by Mitch Mueller et.al “History and Development of the Cycle Rickshaw”,(2nd ed.),1939 [9] Shigley, J.E. 2004. 7th edition, Mechanical Engineering Design. New York: McGrawHill. [10] ALI (American Lift Institute), “Automotive Lift - Purchase Considerations”. July2004 [11] Noor, M.M., Kadirgama, K., Rahman, M.M., Sani, M.S.M., Rejab, M.R.M., 2008. Development of auto car jack using internal car power. Malaysian Science and Technology Congress, pp. 593-598. Owens, M.T. 1998. The Washington Times: USMA report on the Integration and Performance of Women at West Point. [12] Rankine, H.J. 2007. Minister for consumer affairs, Government of South Australia, “Tilting Technologies that can’t stand the strain”2009. Razzaghi, F. and Douglasville, International publication.