CHAPTER 1

INTRODUCTION

Background of the Study

A practical and popular machine for moving products over short distances is the

lift truck, one of the most important, yet overlooked, industrial innovations in modern

times. Today, over 150,000 of these machines are delivered to buyers each year

(MHEDA, 2004).

Powered industrial trucks, commonly called forklifts or lift trucks, are used in

many industries, primarily to move materials. In industries and businesses, the use of

large and heavy items is apparent. The use of forklifts have changed the way in which

businesses and industries thrive. It is a powered vehicle or machine that is designed to

carry, lift or stack materials. They move large and heavy items from one place to

another. It is a heavy-duty machine which is equipped with forks or prongs in its carriage

to be able lift loads on pallets. It is used for the indoor and outdoor movement of

materials. It made transporting heavy loads more convenient (OSHA, 2018).

Due to the varieties of items, different shapes, sizes and packaging of goods,

forklifts were invented as a solution to said problem. Forklifts were designed as a better

option to the older and more dangerous way of moving materials by means of manual

operation of a system of hoists, which were the primary means of lifting and moving

heavy items in the late 1800s. These hoists, essentially chains and winches, gave way

to wooden platform trucks around the turn of the 20th century. Soon after, the wooden

trucks and their trailers incorporated electric motors and traction batteries (MHEDA,

2004).
 It is evident that the former way of moving materials is already dangerous as is.

However, forklifts also pose danger themselves. The National Institute for Occupational

Safety and Health (NIOSH) states that there are three common types of accidents

relating to forklifts. Such are: forklifts overturning, workers being struck, crushed, or

pinned down by a forklift and workers falling from a forklift (NIOSH, 2014).

The hazards commonly associated with powered industrial trucks vary depending

on the vehicle type and the workplace where the truck is used. Each type of truck

presents different operating hazards. For example, a sit-down, counterbalanced high lift

rider truck is more likely than a motorized hand truck to be involved in a falling load

accident, because the sit-down rider truck can lift a load much higher than a hand truck.

Workplace conditions also present different hazards. For example, retail establishments

often face greater challenges than other worksites in maintaining pedestrian safety.

However, with proper training and safety procedures can avoid 70% of accidents

according to the Occupational Safety and Health Administration (OSHA, 2018).

Current designs of forklifts are big and bulky. These type of forklifts require a

bigger working area as well as greater measures for safety. In smaller types of

warehouses, these may not be a very effective way of transporting materials as it may

be limited to outdoor use only. In said types of warehouses or storage areas, weights

that are not relatively heavy but are not easily manipulated by manual labor are usually

transported by means of trolleys or by hand. Safety of latter is questionable as there is

no clear way to prevent hazards. Some materials are moved around by lugging or

throwing around and about the materials especially in higher places with narrow working

areas.
 Due to the commercial importance of the machine, there is room for improvement

in terms of design and safety to reduce the risks posed by pre-existent designs. By

considering said working conditions, an innovation for a compact design is investigated

Objectives

This study aimed to design, construct and test a remote controlled three wheel

forklift for warehouse use

Specifically, this study aimed to:

1. Develop a forklift that will be able to lift a load of not more than sixty (60)

kilograms or one hundred and thirty two (132) pounds

2. Design a wireless remote control system for the machine using

microcontrollers such as Arduino, Raspberry Pi and the like

3. Develop a forklift which can navigate a minimum horizontal clearance of

one (1) meter

4. Develop a compact body design with only three (3) wheels

5. Design the appropriate lifting mechanism

6. Develop a forklift to be able to reach a maximum height of two (2) meters

7. Design the appropriate Counterweight

Significance of the Study

This study will be beneficial to the following:

Forklift operators. They will be able to increase efficiency in the workplace as well

as reduce risks and accidents.

Industries and Warehouses. They will have a more economical and efficient

option for moving around heavy materials.

Future Researchers. They may be able to use the study as the basis of their

research and they could also get some ideas which could help them improve their study.

Engineers. They will have a future reference for anything related to the topic as

well as be able to further innovate the pre-existing designs relating to the machine and

its parts.

Scope and Limitations

This study aimed to test the performance of the design and construction of a

remote controlled three-wheel forklift for warehouse use. This involved the designing of

the following: (1) Lifting mechanism (2) Control System (3) Driving System with only

three wheels (4) Body and (5) Counterweight. The whole machine along with its

subsystems will be a central control system which can be controlled wirelessly with a

range of at least 9 meters or 30 feet. The application of the system is limited to indoor

use or for use on flat surfaces with not much obstructions on the work way. The

construction and fabrication of each subsystem will be based on the maximum range of

values given. The design will be limited to a maximum load of 60 kilograms or 132

pounds, a minimum horizontal clearance of 1 meter or 3.3 feet and a maximum vertical

reach of 2 meters or 6.5 ft.