project report Cycle for a person without hand ie. armless cycle

1. 1
CHAPTER 01
PROJECT IDEA
1. PROJECT IDEA
The idea of this project had come in our mind when I saw a person who suffers from a
problem of disability who‟s both hand was useless and not to work at any stage of his life.
And he has a desire to go for 8 to 10 km so they have option to go by the bus and another
vehicle but if has some luggage (approximately weight 2-3 kg) then he need a person to
support him. At this stage the life of that person was useless now he does not go to anywhere
because of his physical condition. Transportation has become an integral part of people‟s
day to day life. At certain times, in large countries like India , people are forced to
travel long distance from their work place to their place of residence. People with upper
limb amputation and hands have difficulties in travelling and cannot travel these long
distances. They use devices such as wheel chair, crutches and artificial limbs for mobility.
These however cannot be used for long distance outdoor transportation Therefore, the aim of
this project is to design and fabricate „Moving vehicle for a person without hand‟ for armless
people.
The Foot Operated Steering mechanism is a mechanism controlled by foot or both the feet in
order to steer the vehicle in the desired direction. This system consists of a mechanism which
can control vehicle along with steering. The main objective of the project is to design a foot
operated system for handicapped people.
Then the idea had come in our mind that if my team works on that project who helps such
type of problems, which don‟t need a person‟s support and disable person can easily survive
their life.
Since, there are so many handicapped vehicle are present in market which operate many
methods for example chin control, brain operated, hand operated etc.

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But my project covers such type of critical condition for handicapped person and vehicle is
operating by leg response.
Now a days transportation has become great difficulty to and individual to reach the
destination on time. Everyone has their own vehicle and people with all body parts are
fortunate. But it is unfortunate for partially disable people with hands. Disability is the
repercussion of an impairment which can be mental, physical, emotional, vision, sensory.
Disabilities can occur in upper extremities and in lower extremities. These people become
more dependents and lose their confidence. Due to this effect, they stand a great disadvantage
in using public as well as private transportation facilities. Moving vehicle for a person
without hand was something new to come up with and we had an interest to make something
innovative. The main objective of the project is to design a foot operated system for
handicapped people.

3. 3
CHAPTER 02
INTRODUCTION TO PROJECT
Now a days transportation has become great difficulty to and individual to reach the
destination on time. Everyone has their own vehicle and people with all body parts are
fortunate. But it is unfortunate for partially disable people with hands. Disability is the
repercussion of an impairment which can be mental, physical, emotional, vision, sensory.
Disabilities can occur in upper extremities and in lower extremities. These people become
more dependents and lose their confidence. Due to this effect, they stand a great disadvantage
in using public as well as private transportation facilities. Moving vehicle for a person
without hand was something new to come up with and we had an interest to make something
innovative. The main objective of the project is to design a foot operated system for
handicapped people.
Since there are so many methods of operating or controlled the chair for example brain
operated, hand operated, joystick, chin control, etc.
Improved chair mobility could be an important factor in realizing increased independence for
persons unable to walk. Motorized chairs have minimized the physical strain of chair
propulsion, yet in many instances they do not provide adequate input control devices for
certain disabled persons. Some of the conventional powered-chair control concepts that are
commercially available are described, along with three new types of chair controller under
development at APL and results from preliminary clinical evaluation of them.
There are so many methods already present in the market of research field some are as
explaining as-
2.1 CHIN CONTROL CHAIR VEHICLE-
The first type of powered chair controller that has received consideration in the research and
evaluation program at APL is one intended for per- sons with high-spinal-cord injuries. To
control his chair, such a person must use some signal derived from his head; one

4. 4
conventional type of wheel- chair controller for him. This is the Veterans Administration
Rehabilitation Engineering Center (formerly the VA Prosthetics Center) chin controller. It
contains a modified joystick that is positioned for operation by motion of the chin. Moving
the chin up and forward controls forward speed, moving it left or right controls turning, and
moving the controller down and backward controls reverse speed. Although under ideal
circumstances this device allows reasonable control of a chair, its bulk and location in front
of the face are objection- able. The location of the control box also restricts or prevents use of
a mouth stick. Because a mouth stick is a very useful manipulative tool for many high-level
quadriplegics, this feature of the controller is a significant disadvantage.
The control box has been miniaturized and relocated on the back of the wheelchair behind
the user's head and neck. An inconspicuous tubular ex- tension curves around one side of the
neck and terminates just below and in front of the chin. Down- ward motions of the chin
depress this lever, thereby controlling wheelchair velocity. Lateral movements of the lever
provide directional control. A micro- switch at the tip of the chin lever permits selection of
the reverse mode. An electronic interlock circuit inhabits operation of this reverse switch
except when the wheelchair is at rest.
2.2 POWER ASSIST CHAIR VEHICLE-
During 1977, a third type of chair controller was conceived and developed at APL. This
model utilizes input to the wheel rim similar to that involved in hand-propelling a
conventional wheelchair; how- ever, powered assist is provided to minimize the effort of
self-propulsion. Powered assist is achieved by decoupling the hand rims from the drive
wheels so that they can rotate independently and, by using the electric motors, cause the
drive wheel to rotate at the same speed as the hand rim. Transducers are introduced to
measure the velocity of hand rim rotation and to relate this velocity to that of drive wheel
rotation on the same side. The design concept is similar to that of automotive power steering.
This control mode for the motorized chair may improve maneuverability within small spaces,
especially for persons previously accustomed to hand-propelled wheelchairs and who no

5. 5
longer have enough strength and endurance for self-propulsion. Two demonstration models
of this concept have undergone limited testing indoors and outdoors at APL. A volunteer
used one of these models to compare its performance to that of her own manually propelled
wheelchair. She suffered from Friedreich's ataxia and participated in the closed-loop
wheelchair testing described earlier in this report. She felt that the powered assist wheelchair
increased her range and maneuverability to the extent of enabling her to perform specific
tasks otherwise beyond her capability. An example cited was the ability to maneuver through
a grocery store and fill her shopping cart without assistance or exhaustion.

6. 6
CHAPTER 03
NEED OF THIS PROJECT
A national level survey conducted in India by the Central Government of India once in
ten years revealed that, around 27 million people which are about 2.21% of the Indians are
differently able. Among them, around 14.98 million were men while 11.84 million were
women. Thus, the percentage of disabled people in rural area was higher than those in
urban areas. A total of 5.43 million people were identified with disabilities in
movement which was the highest among other categories such as hearing, seeing etc. in
terms of numbers of people affected.
Table: 1 Population of people with disabilities by type of disability
Types Of Disability Males Females Persons
Mental retardation 8,70,708 6,34,916 5,05,624
In hearing 4,15,732 3,07,094 7,22,826
In seeing 26,77,544 23,93,463 50,71,007
In speech 26,38,516 23,93,947 50,32,463
In movement 11,22,896 8,75,639 19,98,535
Any other 33,70,374 20,66,230 54,36,604
Multiple disability 27,27,828 21,99,183 49,27,011
Multiple disability 11,62,604 9,53,883 21,16,487
Total 1,49,86,202 1,18,24,355 2,68,10,557
Transportation has become an integral part of people‟s everyday life. At certain times, in
large countries like India, people are forced to travel more than 15- 20 km from their work
place to their place of residence. People with disabilities in lower extremities and hands have
difficulties in travelling and cannot travel these long distances. They use devices such as

7. 7
wheel chair, crutches and artificial limbs for mobility. These however cannot be used for
long distance outdoor transportation. Therefore, the aim of this study is to design and
fabricate „Foot operated system‟ for armless people. The system will be using “Rack And
Pinion” arrangement, which converts rotary motion into linear motion. The system consists
of wheels, internal threaded cylinder, lead screw, linkages, rotating pinion and rack. This
system is compact and thus will be used for long distance transportation. The main objective
of the project is to design a foot operated system for handicapped people and will be useful in
military purpose. This system will be cost effective and easy to operate.
Table: 2 Disabled populations by sex and residence
Residence Males Females Persons
Urban 45,78,034 36,00,602 81,78,636
Rural 1,04,08,168 82,23,753 1,86,31,921
Total 1,49,86,202 1,18,24,355 2,68,10,557
The key words of this project are-
 Disabled People by ARM Disability
 Foot Operated System
 Travel 15-20 km
3.1 DESIGN CONSIDERATIONS-
 This application can only be used with a slow speed vehicle around 20 km/hr of
speed:
 Since the vehicle is fully controlled by leg itself it is necessary to limit maximum
speed of the vehicle to a safe speed.
 The terrain or the floor must be flat:
 The vehicle is more suitable to flat or terrain path.
 The vehicle is driven by mechanically driven.

8. 8
CHAPTER 04
LITERATURE REVIEW
REVIEW A-
Pranchal Srivastava, Raj Kumar Pal “A Low Cost Mobility Solution for Physically
Challenged People”., International Journal of Mechanical Engineering and Technology
(IJMET) Volume 6, Issue 12, Dec 2015.
The most common approach used in most powered wheelchairs is having two motors for
traction each driving a wheel on either side of the machine. The motion is achieved by
keeping the speeds of the motors identical in one direction and the other direction for reverse
motion. Turns are executed by making the speeds of the motors different. The radius of turn
depends on the speed difference. Turns are executed by making the speeds of the motors
different. This system depicts three novel approaches for cost effectiveness and efficient
working, firstly having a powered wheel chair drive with a gear mechanism which is used to
generate proper speed of the wheels on the either side with single power motor. The
advantage of this system is that it makes the system control easy and cheap. Secondly,
utilization of waste brake energy for battery charging which lead to reduced cost of powered
wheel in the long run.
REVIEW B-
Challenged People Using Arm Processor” International Journal of Mechanical Engineering
and Technology (IJMET) ,Volume 6 , Issue 12, Dec 2015.
The aim of the technology is to help those handicapped who don‟t have healthy hands to run a
vehicle by giving the voice commands. In this the driver need not u se the steering instead his
head. This vehicle is only for those handicapped those who can nod head well. Four switches
are interfaced over the neck of the driver, and the vehicle can be controlled by the head
movement. Corresponding tactile switches are activated according to the movement of the

9. 9
head, and towards the conclusion the practical difficulties are described and the possible
solutions are discussed.
REVIEW C-
Clinical Survey of Upper Extremity Amputees in India.
Brig. I.C. Narang, MS, FICS
Lt. Col. B.P. Mathur, MS, M.Phil. (UK)
Lt. Col. Pal Singh, MS
Mrs. V.S. Jape, MA, MA (SW)
A survey of upper limb amputees has been carried out at the Defense Services Artificial
Limb Centre, Puna, India. The aim of the survey was primarily to gather information directly
from the patients about the utility of upper limb prostheses which are being provided at
present.
Table: 3 Age and gender determination
Age
group
0-10 11-20 21-30 31-40 41-50 51-60 Above
60
Total
Males 2 3 38 45 21 11 4 124
Females - 3 1 2 - - - 6
Total 2 6 39 47 21 11 4 130
REVIEW D-
Dual Steered Three Wheeler For Differently Able People; “Arun Raju C , Anish Raman C ,
Veerappan K.R. Venkat Narayanan

10. 10
The aim of this study is to design and fabricate a 3 wheeler with dual steering system for
people with locomotive disabilities .A greater steering effort is required in the case of a four
wheeler compared to a three wheeler. Hence, a three wheeler was selected instead of a four
wheeler. In this case, handle bar steering system and leg steering system can be
individually steered with hands and legs respectively, enabling its utility people with
disabilities in upper extremities. Sprocket chain system was used in leg steering system. A
98cc Kinetic Honda Engine was used as the power source and the engine was placed towards
the rear end of the vehicle. Single Rated and double rated suspension spring was used in
the front and rear drive shaft respectively. Sprocket chain system was used in leg steering
system.
REVIEW E-
An Efficient Car Driving Controller System Design for Physically Challenged People
Using Arm Processor; “Katari Ramaiah, T. Mallikarjun”
The aim of the technology is to help those handicapped who don‟t have healthy hands to run a
vehicle by giving the voice commands. In this the driver need not use the steering instead his
head. This vehicle is only for those handicapped those who can nod head well. Four
switches are interfaced over the neck of the driver, and the vehicle can be controlled by
the head movement. Corresponding tactile switches are activated according to the
movement of the head, and towards the conclusion the practical difficulties are described
and the possible solutions are discussed.

11. 11
CHAPTER 05
METHODOLOGY, DESIGN & DRAWING
The system consists of an internally threaded pinion and one externally threaded lead screw
which are engaged like nut and bolt arrangement. C-clamp is used to transfer the motion of
lead screw. A rack is connected to C-clamp. The rack is engaged to first pinion. This pinion is
centrally aligned with second pinion. One more rack is connected to this pinion to convert
rotary motion into linear motion. The wheels are at both ends of the rack.
Initially the pinion is rotated in clockwise direction by using left foot. Due to this motion, the
lead screw moves to the left side. C-clamp transfers the motion to the rack. Rack moves along
with C-clamp. The first pinion which is engaged with rack will start rotating in clockwise
direction due to motion of rack. The second pinion also rotates in same direction as the first.
The second pinion again transfers motion to another rack which has wheels at its both the
ends and rack will move in right direction. Due to the motion of rack, the wheels will move to
right direction and vehicle will take right turn. Similarly, when driver rotates pinion in anti-
clockwise direction the exact opposite mechanism will occur and vehicle will take left turn.
This system can be mounted in cars having automatic gear system because the clutch of the
vehicle is to be replaced by lead screw and pinion pair.
There are the following steps consider during designing of the project.
Fig. 5.1 Steps of Methodology

12. 12
5.1 DESIGNING OF MODEL-
All of first design of the model very important for any project going to be manufactured.
There are many component which are to be used in project going to the various loads and
stress due to which various loads are acting on the component of the part of the project so it
5.1.1 HOLLOW SQUARE CROSSECTIONAL SHAPE OF ROD
Since as the section modulus is grater, increase the strength of the beam ie. The value of Z
increases the strength. The section modulus is given by-
Z = section modulus =
 For Square Section-
b = h = 0.5 (NOTE- all dimensions in cm)
I =
=
= 0.0052083333
Z =
Z =
Z = 0.0208333 Φ 0.5
 For Circular Section
I =

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I =
= 0.003067961
Z =
Z =
Z = 0.01227
Since the section modulus of squarer cross-section is grater then the circular cross-section
hence the square cross-section provide more strength as use of the circular hence in my
project we use square cross-section having the width and length 0.5 CM
5.1.2 DESIGN OF SHAFT
Since the load acting on the shaft as shown in the drawing
Fig. 5.2 Analysis of shaft
Let us assume that the weight of the man is 50 kg.

14. 14
Hence,
Total load( W ) = mass x gravity
50 x 9.81
= 490 N
Since the total load ie. 490 N is acting on the center of the shaft
Hence, RA = RB = W / 2
RA = RB = W / 2 = 490 N / 2
= 245 N
Hence,
RA = 245 N
RB = 245 N
Since Ra = Rb = RA /2
Ra = 122.5 N
Rb = 122.5 N
Similarly,
Rc = Rd = RB / 2
Rc = 122.5 N
Rd = 122.5 N
Now,
Bending moment (M) = load x perpendicular distance from load
= 490 x 8 + 245 x 16
= 7840 N.cm

15. 15
From Bending Equetion-
……….(i)
Since,
E/R = M/I…………………………………………….(ii)
Hence,
R = E* I / M
Since modulus of elasticity of dead mild steel is (E) = 200 GPa
Considering factor of safety = 4
So for safe limit,
Es =
= N/m
Hence from equation (ii)..
By putting the above value we can get the value of R
R = D / 2
I =
We get R = 6.23 CM
Hence D = 2 * R = 12.46 CM.
So for safe design we take the shaft diameter (D) = 12.46 cm.
5.1.3 DESIGN OF PROJECT IN 2D VIEWS
The views of the project in two dimensional is given as –
 Side views
 Top views

16. 16
In technical drawing and computer graphics, a multi view projection is a technique of
illustration by which a standardized series of orthographic two-dimensional pictures is
constructed to represent the form of a three-dimensional object. Up to six pictures of an object
are produced (called primary views), with each projection plane parallel to one of the
coordinate axes of the object. The views are positioned relative to each other according to
either of two schemes: first-angle or third-angle projection. In each, the appearances of views
may be thought of as being projected onto planes that form a six-sided box around the object.
Although six different sides can be drawn, usually three views of a drawing give enough
information to make a three-dimensional object. These views are known as front view, top
view and end view. Other names for these views include plan, elevation and section. The
terms orthographic projection and orthogonal projection are sometimes reserved specifically
for multi views. However, orthographic and orthogonal more correctly refer to the right angle
formed between the projection rays and the projection plane, versus the angle formed between
the subject of the drawing and the projection plane. Thus, orthographic projections include
axonometric or auxiliary views in addition to multi views.
All dimensions in cm...
Fig.5.3 Side views of model
Gear

17. 17
Fig. 5.4 Top views of model
5.2 SELECTION OF COMPONENTS
Generally in the project the following components are to be used-
5.2.1 Tubeless Tyres Wheels
 Tubeless tyres, as the name suggests, are tyres without the tube. The tyre is built in
such a way that it can contain the air by itself. It does not require a tube within it.
 The tyre and rim assembly form an air container, to “Seal” and “Contain” the
compressed air inside the assembly.

18. 18
 The tyre has a halo- or chloro-butyl lining on its inside which is airtight. Together with
the airtight joint between the tyre and the wheel, the membrane forms a container that
holds the air for the tyre.
 A valve is fitted on to the rim for inflation or deflation to the assembly.
Fig. 5.5 Tubeless Tyre
5.2.2 Advantages of Tubeless Tyres Use
 Since tube is eliminated, friction between tyre & tube is not experienced, thus lover
rolling resistance, less vibration and better comfort.
 Chance of tube getting pinched under the bead while mounting is eliminated.
 The number of components used in a tyre wheel assembly gets reduced.
 The tube and the flap are both eliminated.
 Lower tyre/wheel weight (un-sprung mass) results in better vehicle handling and
therefore longer life.
5.2.3 GEAR
 A gear or cogwheel is a rotating machine part having cut teeth, or in the case of a
cogwheel, inserted teeth (called cogs), which mesh with another toothed part to

19. 19
transmit torque. Geared devices can change the speed, torque, and direction of a power
source. Gears almost always produce a change in torque, creating a mechanical
advantage, through their gear ratio, and thus may be considered a simple machine. The
teeth on the two meshing gears all have the same shape. Two or more meshing gears,
working in a sequence, are called a gear train or a transmission. A gear can mesh with
a linear toothed part, called a rack, producing translation instead of rotation. The gears
in a transmission are analogous to the wheels in a crossed, belt pulley system. An
advantage of gears is that the teeth of a gear prevent slippage. When two gears mesh,
if one gear is bigger than the other, a mechanical advantage is produced, with the
rotational speeds, and the torques, of the two gears differing in proportion to their
diameters. In transmissions with multiple gear ratios such as bicycles, motorcycles,
and cars the term "gear" as in "first gear" refers to a gear ratio rather than an actual
physical gear. The term describes similar devices, even when the gear ratio is
continuous rather than discrete, or when the device does not actually contain gears, as
in a continuously variable transmission. Gear wheel is a disc of suitable thickness
having a unique profile on its peripheral that mesh with another similar disc lying on
another shaft. They r used to transmit power from one rotating shaft to another.
 Transmission can be
 Parallel
 Angular
 Right Angled
Fig. 5.6 Gear

20. 20
5.2.4 GEAR NOMENCLATURE
Fig. 5.7 Nomenclature of gear
5.2.5 PINION
A pinion is a round gear usually to the smaller of two meshed gears used in several
applications, including drivetrain and rack and pinion systems, as well as wheel gear and
pinion.
Fig. 5.8 Pinion

21. 21
5.2.6 PEDAL WHEEL
The pedals which are used in the project are of plastics material which have own advantages
so that the overall weight of the vehicle might be reduced.
Fig. 5.9 Wheel Pedal
5.2.7 CYCLE CHAIN
A chain is a serial assembly of connected pieces, called links, typically made of metal, with an
overall character similar to that of a rope in that it is flexible and curved in compression but
linear, rigid, and load-bearing in tension. A chain may consist of two or more links. Chains
can be classified by their design, which is dictated by their use.
Those designed for lifting, such as when used with a hoist; for pulling; or for securing, such as
with a bicycle lock, have links that are torus shaped, which make the chain flexible in two
dimensions (The fixed third dimension being a chain's length.) Small chains serving as
jewelry are a mostly decorative analogue of such types.
Those designed for transferring power in machines have links designed to mesh with the teeth
of the sprockets of the machine, and are flexible in only one dimension. They are known as
roller chains, though there are also non-roller chains such as block chain.

22. 22
Fig. 5.10 CYCLE CHAIN
5.2.8 HOLLOW SQUARE SHAPE LOW MILD STEEL ROD
A hollow structural section (HSS) is a type of metal profile with a hollow cross section. The
term is used predominantly in the United States, or other countries which follow US
construction or engineering terminology. HSS members can be circular, square, or rectangular
sections, although other shapes such as elliptical are also available. HSS is only composed of
structural steel per code. HSS is sometimes mistakenly referenced as hollow structural steel.
Rectangular and square HSS are also commonly called tube steel or box section. Circular HSS
are sometimes mistakenly called steel pipe, although true steel pipe is actually dimensioned
and classed differently from HSS. (HSS dimensions are based on exterior dimensions of the
profile; pipes are also manufactured to an exterior tolerance, albeit to a different standard.)
The corners of HSS are heavily rounded, having a radius which is approximately twice the
wall thickness. The wall thickness is uniform around the section.

23. 23
Fig. 5.11 Hollow square shape mild steel rod
5.2.9 DEAD MILD STEEL SHEET METAL FOR FRAME
You are unlikely to work with Dead Mild Steel in the Metalwork room, however it is useful to
know some information about it. Dead Mild Steel has a carbon content of between 0.05% and
0.15%. This gives Dead Mild Steel the property of good Ductility and the ability to be easily
formed. Some of the uses of Dead Mild Steel are Tinplate, Car Bodies, Chains, Nails, Thin
Wire, etc.
Fig. 5.12 Mild steel sheet metal
5.2.10 FREE WHEEL
In mechanical or automotive engineering, a freewheel or overrunning clutch is a device in a
transmission that disengages the driveshaft from the driven shaft when the driven shaft rotates
faster than the driveshaft. An overdrive is sometimes mistakenly called a freewheel, but is
otherwise unrelated. The condition of a driven shaft spinning faster than its driveshaft exists
in most bicycles when the rider stops pedaling. In a fixed-gear bicycle, without a freewheel,
the rear wheel drives the pedals around.

24. 24
Fig. 5.13 Free wheel
5.2.11 BREAK, WIRE AND HORN
A brake is a mechanical device that inhibits motion by absorbing energy from a moving
system. It is used for slowing or stopping a moving vehicle, wheel, axle, or to prevent its
motion, most often accomplished by means of friction. In this project break wire is used for
breaking system and electric horn provided as small scale.
5.3 MANUFACTURING AND ASSEMBLY
5.3.1 MANUFACTURING
The process of converting raw materials, components, or parts into finished goods that meet a
customer‟s expectations. Manufacturing commonly employs a man – machine setup with
division of labor in a large scale production. Manufacturing is the production of products for
use or sale using labor and machines, tools, chemical and biological processing, or
formulation. The term may refer to a range of human activity, from handicraft to high tech,
but is most commonly applied to industrial design, in which raw materials are transformed
into finished goods on a large scale. Such finished goods may be sold to other manufacturers
for the production of other, more complex products, such as aircraft, household appliances,
furniture, sports equipment or automobiles, or sold to wholesalers, who in turn sell them to
retailers, who then sell them to end users and consumers. Manufacturing engineering or
manufacturing process are the steps through which raw materials are transformed into a final

25. 25
product. The manufacturing process begins with the product design, and materials
specification from which the product is made. These materials are then modified through
manufacturing processes to become the required part.
5.3.2 Various Manufacturing Process
 MACHINING Tools used for machining are immobile power-driven units used to
form or shape solid materials, specifically metals. The forming is done by removing
extra materials from a work-piece. Machine tools make up the foundation of advanced
industry and are utilized either indirectly or directly in the manufacturing of tool parts.
 JOINING Every joining approach has particular design needs, while certain joint
needs may propose a particular joining approach. Design for assembly, and fastener
selection apply their own specifications. Bolting is a standard fastening method, for
instance, but welding may cut down the weight of assemblies. Naturally, joints
intended for the two approaches would differ tremendously However, all joint patterns
must consider features such as load factors, assembly effectiveness, operating
surroundings, overhaul and upkeep, and the materials chosen. Welding is generally a
cost-effective approach to fabricate. It doesn't require overlapping materials, and so it
removes excess weight brought on by other fastening methods. Fasteners don't have to
be purchased and stored in stock. Welding also can minimize costs related to extra
parts, for example angles mounted between parts.
 FORMIMG Metal forming is the approach of creating the metallic components by
deforming the metal but not by removing, cutting, shredding or breaking any part.
Bending, spinning, drawing, and stretching are a few important metal forming process
in manufacturing. The metal press such as die and punching tools are implemented for
this manufacturing process.
 CASTING is a manufacturing process in which a solid is dissolved into a liquid,
heated to appropriate temperature (sometimes processed to change its chemical
formula), and is then added into a mold or cavity. Thus, in just one step, complex or

26. 26
simple shapes can be crafted from any kind of metal that has the capability to be
melted. The end product can have practically any arrangement the designer wants.
 ARC WELDING is a welding process that is used to join metal to metal by using
electricity to create enough heat to melt metal, and the melted metals when cool result
in a binding of the metals. It is a type of welding that uses a welding power supply to
create an electric arc between a metal stick ("electrode") and the base material to melt
the metals at the point of contact. Arc welders can use either direct (DC) or alternating
(AC) current, and consumable or non-consumable electrodes.
The welding area is usually protected by some type of shielding gas, vapor, or slag.
Arc welding processes may be manual, semi-automatic, or fully automated. First
developed in the late part of the 19th century, arc welding became commercially
important in shipbuilding during the Second World War. Today it remains an
important process for the fabrication of steel structures and vehicles.
5.3.3 ASSEMBLY PROCESS
The process of collecting various parts, man or machine in an arrangement so that they form a
smooth structure is called as the assembly. Assembly may be automatic or by means of
manual. An arrangement of workers, machines, and equipment in which the product being
assembled passes consecutively from operation to operation until completed. Also called
production line.

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CHAPTER 06
COST ANALYSIS
Cost estimating may be defined as the process of determining the probable cost of
product therefore the start of its manufacturing. Cost estimation takes into
consideration all expenditure involved in design and manufacturing with all related
services such as pattern making, tool making as well as a portion of the, general
administrative and selling expenses.
Cost estimation involves the knowledge of following factors for calculating the
probable cost of the product.
 Design time
 Amount of material required
 Production time required
 Labor charges
 Cost of machinery, overheads and other expenses
 Use of previous estimates of comparable parts
 Effect of volume of production on costing rates
 Effect of changes in facilities on casting rates
6.1 PURPOSE OF COST ESTIMATION
 To determine the cost of each article
 To determine the cost of uncured during each operation to keep control over
worker wages.
 To provide the information to ascertain the selling price of the product
 It helps in reducing total cost of manufacturing
 It suggest changes in design when the cost is high

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6.2 TYPPES OF COST
The main types of costs involved in cost of production and revenue. The costs are
 Fixed cost
 Variable cost
Cost refer to the prices paid to the factors of production, We find prices paid to fixed
factors and the prices paid to the variable factors which are termed as the fixed costs
and the variable costs respectively. Thus the cost of production of a commodity is
composed of two types of costs, i.e, variable costs and fixed costs, also called prime
and supplementary costs respectively.
6.2.1 FIXED COSTS OR SUPPLEMENTRY COSTS
In economics, fixed costs, indirect costs or overheads are business expenses that are
not dependent on the level of goods or services produced by the business. They tend to
be time-related, such as interest or rents being paid per month, and are often referred
to as overhead costs. This is in contrast to variable costs, which are volume-related
(and are paid per quantity produced) and unknown at the beginning of the accounting
year. For a simple example, such as a bakery, the monthly rent for the baking
facilities, and the monthly payments for the security system and basic phone line are
fixed costs, as they do not change according to how much bread the bakery produces
and sells. On the other hand, the wage costs of the bakery are variable, as the bakery
will have to hire more workers if the production of bread increases. Economists
reckon fixed cost as an entry barrier for new entrepreneurs. In management
accounting, fixed costs are defined as expenses that do not change as a function of the
activity of a business, within the relevant period. For example, a retailer must pay rent
and utility bills irrespective of sales. In marketing, it is necessary to know how costs
divide between variable and fixed costs. This distinction is crucial in forecasting the
earnings generated by various changes in unit sales and thus the financial impact of

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proposed marketing campaigns. In a survey of nearly 200 senior marketing managers,
60 percent responded that they found the "variable and fixed costs" metric very useful.
Fixed costs are not permanently fixed; they will change over time, but are fixed, by
contractual obligation, in relation to the quantity of production for the relevant period.
For example, a company may have unexpected and unpredictable expenses unrelated
to production, such as warehouse costs and the like that are fixed only over the time
period of the lease. By definition, there are no fixed costs in the long run, because the
long run is a sufficient period of time for all short-run fixed inputs to become variable.
Investments in facilities, equipment, and the basic organization that cannot be
significantly reduced in a short period of time are referred to as committed fixed costs.
Discretionary fixed costs usually arise from annual decisions by management to spend
on certain fixed cost items. Examples of discretionary costs are advertising, insurance
premier, machine maintenance, and research & development expenditures.
Discretionary fixed costs can be expensive.
In business planning and management accounting, usage of the terms fixed costs,
variable costs and others will often differ from usage in economics, and may depend
on the context. Some cost accounting practices such as activity-based costing will
allocate fixed costs to business activities for profitability measures. This can simplify
decision-making, but can be confusing and controversial. In accounting terminology,
fixed costs will broadly include almost all costs (expenses) which are not included in
cost of goods sold, and variable costs are those captured in costs of goods sold under
the variable costing method. Under full (absorption) costing fixed costs will be
included in both the cost of goods sold and in the operating expenses. The implicit
assumption required to make the equivalence between the accounting and economics
terminology is that the accounting period is equal to the period in which fixed costs do
not vary in relation to production. In practice, this equivalence does not always hold,
and depending on the period under consideration by management, some overhead
expenses (e.g., sales, general and administrative expenses) can be adjusted by

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management, and the specific allocation of each expense to each category will be
decided under cost accounting.
Table 4 Fixed cost
Serial no. Monthly (in Rs.)
1 Rent of building 20000
2 Light 2000
3 Insurance 1000
4 Deprecation 500
5 Capital investment 200000
6 Advertisement 5000
Total fixed cost = 228500 Rupees, Annually fixed cost = 228500 x 12 = 2742000 Rupees.
6.2.2 VARIABLE COST
A variable cost is a corporate expense that changes in proportion with production output.
Variable costs increases or decrease depending on a company‟s production volume, they rise
as production increases and fall as production decreases.
Table 5 Material cost for one unit
Serial no. Part/
component
No. of
component
Cost per
piece
Total cost
1 Rod 5 160 480
2 Wheel 3 100 300
3 Electrode 1 180 180
4 Gear 1 50 50

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Material cost for 19200 unit = 19200 X cost per unit
= 19200 X 1010
= 19392000
Table 6 Other Cost
Serial no. Salary in
Rupees
Required
quantity in
no.
Total ( in
one year )
1 Worker 16000 per
month
15 2880000
2 Labor 300 per day 20 1800000
3 Shipping cost Its depend on
distance
Total variable cost = 19392000 + 4680000
= 24072000
Total cost = variable cost + Fixed cost + Packaging
= 24072000 + 2742000 + 2400000
= 29214000 Rupees
No of units produce in one month = 550
Now in one year no of units produce = 550 X 12 = 6,600
Now cost per unit = Total cost / no. of units
= 29214000 / 6600
= 4,426.36 Rupees only
Result: Cost per piece = 4,426.36 Rupees only.

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CHAPTER 07
RESULTS
7.1 ADVANTAGES
 If a handicapped by hand person want to go 5 to 10 km in villages and he has
luggage then he can easily go their without any supports.
 Basically this project very beneficial for the village‟s handicapped person
where don‟t have Auto-riksha and other transportation.
 More reliable
 More smooth
 Life of handicapped by hand person has their desirable life.
7.2 APPLICATIONS
 Revolution in the field of cycle for a person without hand.
 A person without hand can easily take 4 – 5 kg luggage with him.
7.3 FUTURE SCOPE
 There is the grate revolution in the life of such person.

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REFERENCES
 Wikipedia
 Arun Raju , Anish Raman, Veerappan K.R.Venkat Narayanan; “Dual steered
three wheeler for differently able people”, European Scientific Journal May
2014 edition vol.10, no.15 Issn: 1857 – 7881 (print) e - Issn 1857- 7431.
 Major General Vijay Pawar and Dr. George Judah, A Study on the
Rehabilitation Facilities Provided by the Government to People with
Disabilities & Its Awareness in the Society, International Journal of
Management, Volume 5, Issue 8, 2014, pp. 16 - 24.
 V. B. Bhandari; “Design of machine elements”, Reference book.