DESIGN DEVELOPMENT OF AN INDIGENOUS TRICYCLE RICKSHAW
B: Tricycle for Physically challenged users
3.1.7 Prototyping of the trike
Fig. 3.22 Top view with mannequin in CAD Fig. 3.23 Rear view with mannequin in CAD
Fig. 3.24 Three quarter front view of trike Fig. 3.25 Three quarter rear view of trike
Material used for fabrication of the prototype is shown in Table 3.3, p 71. For facilitating prototyping process, full scale tape drawing was carried out to check various factors such as form, height, width and proportion. After ascertaining these data, the actual fabrication of the frame was completed through a small workshop in Guwahati (Fig. 3.28- 3.31) specialising in tubular fabrication. Outside the Department of Design, IIT Guwahati workshop facility was utilized, since all the required facilities were not immediately available in the department at that time specifically 3 roller type pipe bending machine.
Rest of the prototyping work including fitting of the sub-systems and components was carried out in the department. Total fabrication cost comes to Rs. 6,909.00 of which details are shown in Tables below.
Table 3.2, p 71 enlists the parts procured from the available components in the market.
Table 3.3, p 71 enlists various materials procured from multiple sources.
Table 3.4, p 72 enlists Labour charges for fabrication of a newly designed Trike for disable persons on job work basis.
The Tables 3.2 to 3.4 provides a comprehensive idea about the possibility of implementing the design commercially with ease, since it conveys a clear information about the components required and its availability locally.
Fig. 3.28 Prototyping of the Trike Fig. 3.29 Prototyping of the Trike in progress
Fig. 3.30 Prototyped Body shell of the Trike Fig. 3.31 Prototyped Body shell of the Trike
Side view 3 quarter front view
In mass production, with setting up of proper manufacturing facilities, the cost is expected to come down to a considerable amount. Local enterprises may take up this exercise, an aspect that is discussed in Chapters 6 and 7.
Table 3.2 Standard items bought out from existing bicycle and tricycle industry (Price as on 1.1.2004 in Guwahati)
Sl. no. Description of materials Rate per unit Rs.
Quantity Amount Rs.
1 Mountain bike rim10 gauge 26” dia 130.00 each 3 nos. 390.00 2 10 gauge spokes 36 nos. x 3 180.00 per gross 108 nos. 135.00
3 10 gauge front hub 36 spokes 30.00 each 1 no. 30.00
4 10 gauge back hub 36 spokes 35.00 each 1 pair 70.00
5 B/bull heavy duty tyre 26”X 1.75” 125.00 each 3 nos. 375.00
6 Ralson ml tube 26”X 1.75” 30.00 each 3 nos. 90.00
7 Front mud guard 45.00 each 1 no. 45.00
8 Rear mud guard 45.00 each 2 nos. 90.00
9 Fork 150.00 each 1 no. 150.00
10 Screw racer 10.00 per set of 2 1 set 10.00
11 Ball racer 10.00 per set of 2 1 set 10.00
12 ¼ ball Apollo 15.00 per packet 1 packet 15.00
13 Handle 150.00 each 1 no. 150.00
14 Rickshaw frame brake set 35.00 per set 1 set 35.00
15 Bell 20.00 each 1 no. 20.00
16 Handle fitted Rear view mirror 20.00 each 2 nos. 40.00 17 Rear Axle with Freewheel socket
(Specially fabricated)
300.00 each 1 set 300.00 18 Brake set from mountain bike 100.00 per set 2 sets 200.00
19 BB socket 20.00 each 1 no. 20.00
20 BB axle Black 20.00 each 1 no. 20.00
21 BB cup Black 20.00 per set 1 set 20.00
22 Gear crank -48 T 95.00 per set 1 set 95.00
23 Pedal 45.00 per pair 1 pair 45.00
24 Cotter pin 2.50 each 2 nos. 5.00
25 5/4 ball center 10.00 per packet 1 packet 10.00
26 22 teeth freewheel 30.00 each 1 no. 30.00
27 Freewheel plate 27 teeth 10.00 per set 1 set 10.00
28 Heavy duty bicycle chain 65.00 each 1 no. 65.00
29 Heavy duty frame cup 5.00 per set 1 set 5.00
30 Frame socket 5.00 each 4 nos. 20.00
31 Head pipe 10.00 each 1 no. 10.00
32 Lock 20.00 each 1 no. 20.00
33 Rear end reflector 5.00 each 2 nos. 10.00
34 Shell type Seat complete 100.00 each 1 no. 100.00
Total: A 2,640.00 Table 3.3 Items procured from various sources
Sl no. Description Rate
Rs.
Quantity Amount Rs.
1 MS tubes 19.0 mm dia, 170 gms/RFt 40.00/kg 90 RFt-15.3 kg 612.00 2 MS tubes 25.4 mm dia, 350 gms/RFt 40.00/kg 3 RFt- 1.0 kg 40.00 3 MS flat 25.4 X 4 mm, 180 gms/RFt 40.00/kg 10 RFt- 1.8 kg 72.00 4 MS tube 50.0 mm outer dia 50.00/kg 2 RFt- 2 kg 100.00 5 MS perforated sheet 20 Gauge 450.00/sq.mt 0.5 sq.mt 225.00 6 Aluminium sheet for floor 450.00/sq.mt 0.6 sq.mt 270.00 7 Acrylic sheet for the front end 3’ X 4’ 500.00/sq.mt 1.1 sq.mt 550.00 8 Canvas for hood, rain guard flap etc. 100.00/m 4 meters 400.00
9 Welding rods 100.00/pkt 1 packet 100.00
10 Assorted Nuts and bolts etc. 100.00/kg 1 Kg 100.00
11 Duco automotive putty 200.00/kg 0.250 Kg 50.00
12 Duco primer & surfacer 150.00/ltr 1.0 litre 150.00
13 Duco paints 300.00/ltr 1.0 litre 300.00
14 Duco thinner 200.00/ltr 1.5 litre 300.00
Table 3.4 Labour charges for fabrication of a newly designed Trike for disable person (on job work basis)
Sl.
No
Description Rate
Rs.
Quantity Amount Rs.
1 Bending 50.00 Per Trike 50.00
2 Cutting & grinding 200.00 Per Trike 200.00
3 Welding & grinding 300.00 Per Trike 300.00
4 Painting 200.00 Per Trike 200.00
5 Fitting of wheels with spokes, balancing 50.00 Per Trike 50.00 6 Fitting of gears, axles, chains, handles, fork 100.00 Per Trike 100.00
7 Stitching of hood 100.00 Per Trike 100.00
8 Fitting Seats, front wind shield etc. 50.00 Per Trike 50.00 Total: C 1,050.00 Total (A+B+C) 6,909.00 3.1.8 Trials of the trike and findings
Once the functional prototype was ready, it was extensively tested for its performance, stability, convenience, comfort etc. (Fig. 3.32), which was also been tested with children (Fig. 3.33) to see with less physical strength and body size, if the trike suits them, then the shape, assumed to fit the disable users.
Fig. 3.32 Trike under Trial Fig. 3.33 Trike ridden by kids
Fig. 3.34 Trike in side view Fig. 3.35 Trike in three quarter front view
Fig. 3.36 Trike in top view Fig. 3.37 Trike in front view Fig. 3.38 Trike in rear view The findings are as under:
• The operation of the trike was found to be very easy and comfortable by adults as well as children. This was very much evident from the fact that during its testing, many children from the campus rode this trike with ease (Fig. 3.33, p 72) not only alone but with hordes of them at the same time.
• In terms of aesthetics, common view from the persons who experienced by riding and many others who opined on the new trike liked it due to its form. The trike looks best at its side view (Fig. 3.34, p 72) and 3 quarter views (Fig. 3.35, p 72). In these views, the trike achieved the desired visual identity of being contemporary, sophisticated, sporty and dynamic. It was felt that its top (Fig. 3.36), front (Fig. 3.37) and rear (Fig. 3.38) views appeared to be static. This could be attributed to its prototyping process and skill available with the local workshop. Fabricating a 3 dimensional curved frame was found to be difficult for the persons available in the workshop. Refinement in achieving the smoothness may be taken care in due course of further development for manufacturing. Till this level, the concept’s acceptability is tested.
• From the point of view of Human Factors and ergonomics criteria and strive for improving upon them, the result could be best described as mixed. This can be attributed to the design of the trike that was towards recumbent bike but required to ride conventional way by pedaling with foot and steering with the hands.
• The trike provided easy access to the able bodied user but for ease of access by the disable user to get in and out of the tricycle, swivel seat that can turns to the side needs to be incorporated.
• The trike provides easy maneuverability, keeping up to the present day transportation needs. The tricycle designed was able to take quick turns and acquires lesser space on road. However its wheel track was found to be less and there was a tendency at higher speed to get destabilized during sharp turning. Wheel track needed to be increased.
The safety enclosure and the overhead structure were integrated and acts like a rolling cage to provide protection to the user in case of over turn. It provided protection to the user from the elements of nature without increasing the weight of the tricycle excessively. It also provided protection to the user from accidents resulting out of crashes by other vehicles during operation on the road to some extent through the enclosure so that no other vehicle will directly hit the user of the tricycle.
Tricycle design was carried out to use high strength thin profile Mild Steel tubes welded through arc welding. As an anti corrosion measures, this was treated with anti corrosion treatment and in the first functional prototyping, coated with automotive paint through spray painting process. However it was designed for powder coating either in epoxy or polyester based material or even dip coated in these materials. Trike can also be made in stainless steel, aluminium or similar materials to reduce its weight. If desired, the materials can be precisely cut through laser cutting machine and assembled through robotic assembly lines and thus the trike can be manufactured by using local expertise as well as the modern technologies and materials.
It was found that during trial of the trike, many people wanted to know the availability of the trike, its cost and expressed keen desire to purchase it even by paying in advance.
As this work is still in developmental stage, a concept further detailing and looking for appropriate arrangement for its manufacturing and marketing was not carried out. The process for modification of the trike to a disable person’s tricycle is being continued as well as conversion in combination with other power sources and experiments as a solar powered electric tricycle is being taken up as a separate project attempt. The experience gained here in led to the designing of a tricycle rickshaw for passengers, which is the main emphasis of this thesis work.
Designing of a Tricycle Rickshaw for Passengers
For a citizen living in South East Asia, a tricycle rickshaw is an existing product.
Therefore designing a tricycle rickshaw may be thought as a redesign exercise. Thus extreme caution is to be taken for its design under this research work so that context for its design is not lost. In this case although existing tricycle rickshaw was studied, except the concept of a tricycle the design work initiated was fresh and started from scratch.
The only similarity between the traditional rickshaw and the newly designed tricycle rickshaw is that it is also a tricycle.