Electric Stairs Climbing Trolley

The Electric Stairs Climbing Trolley is an innovative material handling solution designed to overcome the physical limitations of traditional hand trucks when navigating vertical obstacles. Manual transportation of heavy loads across multi-level structures often poses significant ergonomic risks and operational inefficiencies. This project presents the design and fabrication of a motorized trolley utilizing a Tri-Star wheel mechanism to automate the ascent and descent of staircases, thereby enhancing safety and productivity in logistical tasks. The system is built upon a robust mild steel chassis constructed from 40x40x5mm angle sections, ensuring structural integrity under load. The core locomotion is provided by two planetary wheel assemblies, each featuring three 175mm diameter wheels mounted on a custom-fabricated 4mm steel star bracket. Propulsion is delivered by dual 36V, 60 RPM worm gear motors, which provide the high torque necessary for climbing. The power transmission system employs a chain-drive reduction, linking an 18-tooth freewheel sprocket on the motor shaft to a 44-tooth sprocket on the main 20mm drive rod.