The document describes the design of a low-cost Karakuri-based dolly frame stacking and unstacking system. The aims are to improve efficiency and ergonomics at the workstation. A CAD model and simulation are designed in Solidworks. Stress analysis determines the stopper gate can withstand the force of rolling frames. An electronic counting unit using an Arduino, sensors and display is designed to count frames. Components include conveyor rails, wheels, and profiles from the Minitec catalog. The minimum conveyor inclination angle is calculated to be 9 degrees.

1. KARAKURI BASED DOLLY
FRAMES
Rajabather Arulvadivel Anshumanraj
Student
Assoc. Prof. Inga Skiedraite
Supervisor

2. 2
Aim:
The aim of this project is to design a Low cost Karakuri-based
dolly frame unstacking and frame counting system to improve
the efficiency and ergonomics of the workstation.
Tasks:
1. To design a cad model and simulation of the system in
Solidworks.
2. To calculate the the minimum inclination angle of the conveyor.
3. To analyse the stress and strain in critical parts of the conveyor
system.
4. To design an electronics system to count the number of frames
used in a session.

3. 3
INTRODUCTION
A Karakuri based dolly frames stacker and unstacker is designed to stack
and destack the frames to the conveyors in an efficient way avoiding
manual picking and placing from the box. The system provides more
efficient and ergonomic way of material handling.
Fig. 1. Frames stacking box in assembly line

4. 4
PROTOTYPE OF DESIGN 1
The design of the prototype consists of stacking space at that top where the dolly frames can
be stacked before the work starts. The angle of the racks and conveyor is specially designed.
The design in made in such a way that the frames flow automatically through gravity and
roller guidelines
Fig. 2. Design proposal 1: 1 – workers position, 2 – gate position, 3 –
articulation area, 4 – Elevating conveyor, 5 – frame detector position

5. 5
SIMULATION OF PROTOYPE DESIGN 1
The simulation of the design is done using Solidworks motion analysis.This simuations is
created to provide better understanding of the mechanical movements of the frames concept
in Karakuri design.A total of twenty tasks is created on the solidworks motion analysis
Event based motion view.
Fig. 3. Simulation of prototype 1

6. PROTOTYPE OF FINAL DESIGN
6
The design consists of 4 x 4 racks, so 16 frames can be stacked at a time.The elevating
conveyor rises due to potential energy created by the weight on the other side and acts as
an elevator.
The maximum height of the model is 1.8 meters , length and breadth being 0.94 meter and
2.06 meters respectively. The racks are place at a height of almost 1 meter from the floor ,
with the height of entire rack structure being 0.54 meter.
Fig. 5. Design proposal 2 dimesnions (mm)
Fig. 4. Design proposal 2

7. Main Features of the software:
• System independent 3d design tool for Minitec
components.
• Planning and design of components and systems
regardless of CAD software.
• Electronic Catalog and automatic parts lists
• Direct interfaces with all the most common CAD systems,
such as Mechanical Desktop, ProEngineer, Solid Works,
Solid-Edge and MegaCAD
• More than 180 data output formats in 2d and 3d.
• Automated design modules for workbenches, linear axes,
conveyors, roller conveyors, protective devices
• 90% saving of time for users
• Allows faster assembly of components
7
MINITEC ICAD ASSEMBLER
Fig. 6. Minitec iCAD assembler‘s GUI

8. CALCULATION OF MINIMUM
INCLINATION ANGLE
8
The major design calculations involved are to determine the force required to overcome the resistance
to motion of the loads and the angle of inclination required for a gravity conveyor. Total resistance to
motion is made up of:
• Resistance to rolling of the load on rollers due to friction.
• Frictional resistance in the roller bearings.
• Resistance due to sliding of the load on the rollers and force required for imparting kinetic energy to
rollers.
Resistance to rolling of the total load ‘‘G’’ on the rollers is given by F1 = Gk/R .
where k = rolling friction factor also called coefficient of rolling resistance, mm R = roller radius,mm
Frictional resistance on roller journals is expressed by F2 = (G + wn′) μr/R ...
Where, w = weight of rotating part of each roller. n′ = number of rollers supporting a total load, and
hence in motion. μ = coefficient of friction at the journal. r = journal radius.
Resistance due to sliding of the load on the rollers is given by F3 = {q×(Z0nwv2/gLG)}

9. CALCULATION OF MINIMUM
INCLINATION ANGLE
9
The minimum inclination angle ‘β’ of the gravity conveyor:
Pitch = 50mm
Total length of the conveyor for one frame = 600 mm
Number of rollers necessary = 8
= π/4 × h × (D1 2 -D2 2 )
= π/4 × 25 × (28 -5 ) = 451.375 mm3
Weight of the rotating part of the roller = density of steel × Volume =
=0.0000078 g/mm3 × 451.375mm3
=0.0035 g
tanβ=(2k/D)+[{1+(wn′/G)}×(μd/D)]+{q×(Z0nwv2/gLG)}=
= 0.1604 β
= 9.11° ≈ 9 °
k = rolling friction factor (steel-steel) =
0.0010m = 1.0mm
D = roller diameter = 28mm
w = weight of the rotating part of the roller =
0.007g =0.000007 kg
n′= 3 G = total load = 6kg
μ = coefficient of friction at the journal = 0.5
d = journal diameter = 30mm q = factor of
value between 0.8 to 0.9, because not all the
mass of the roller moving parts is on the
periphery, and thereby not moving with
velocity
v = 1 (assumed)
Z0 = numbers of loads moving simultaneously
on the conveyor = 1 (assumed)
n = number of rollers= 20 v = linear velocity of
the load = 0.2 m/s (assumed)
g = acceleration due to gravity = 9.81 m/s2
L = total length = 0.6m

10. STRESS ANALYSIS OF STOPPER
10
A stopper is designed and mounted on the handle profile to control and stop the flow of
frames. Annealed steel is used to design the stopper.The stopper is placed on the end of
eack racks so a total of four stoppers is used for the design. The main parts used is a handle
connecter, circlar rod and a fastener. A Solidworks stress analysis is performed to check if
the given material is able to withstand the force of 9.01N exerted by the rolling of
frames.The exerted von misses stress is 9.699e +07 which is under the limit of yield
strength 2.920e +08
Fig. 8. Solidworks stress analysis static study
Fig. 7. Placing of stopper

11. 11
COMPONENTS USED FOR THE
ASSEMBLY
Fig. 9. Handle profile Fig. 10. Support flange Fig. 11. Profile 45 X 45
Fig. 12. Swivel casters wheel Fig. 13. roller rail Fig. 14. Counterweight

12. 12
FRAME VALIDATION
COUNTER

13. 13
ELECTRONICS
COMPONENTS
USED:
• Arduino microcontroller
• Infrared sensor
• 16x2 I2C Lcd display
• Jumper wires
• PCB board
• 9v battery
• LED
• Buzzer
• Resistor (220 ohm)

14. 14
ALGORITHMN OF
MICROCONTROLLER PROGRAM
Start
Reading input
from infrared
sensor
Sensor
detection
Increment frame
count
Display to
LCD frame
count
Check if frames per
minute is
maintained
Turning on
alarm (Buzzer
and LED)
Pushbutton
for new
session
End``
NO
YES
YES
NO
Display to LCD
“Starting new
session”
“
YES
Fig 15. Algorithmn of microcontroller program

15. 15
ARDUINO SCHEME AND PCB
An arduino schematic diagram and a PCB board is designed using the software Kicad
(5.1.10 version ). The main reason to design a PCB is to reduce the wiring presnt in the
system and make it conviniently packed. The PCB board is exported to the solidworks in
STEP format This board is later attached to the Karakuri design
Fig. 16. Arduino schematic diagram
Fig 17. PCB board and components 3d view

16. 16
HOUSING AND PLACING ELECTRONIC
COMPONENTS
A mounting top and a base is 3d printed using Prusa MK3S+ 3d printer.The
material used for the design is PLA plastic. The unit is mounted in a such a
way that the infrared sensor can detect passing frames and it can be safely
accessed by worker.
Fig 18. Mounting of case onto electronic components
Fig 19 . Placing of electronic unit onto Assembly

17. 17
PRICE OF THE COMPONENTS
Minitec
article
number
Part name Total Length Unit Price
(euros)
20.1006 Profile 45x45 26645 mm 25 372.84
20.1088 Handle
profile
32572 mm 39 162.45
22.1016 Support
flange
- 53 193.19
32.0550 Roller rail 40140 54 331.00
21.0031 Swivel caster
wheel
- 7 91.67
Table 1. Price of components

18. 18
1. The Cad model of the Karakuri system is designed in
Solidworks using the standard components from Minitec
and the simulation is created using Solidworks motion
analysis.
2. The required minimum inclination angle for the conveyor
is calculated and it turned out to be 9 degrees
approximately.
3. The stress analysis is done for the stopper gate of to
determine the force it can withstand during rolling of
frames.
4. The electronic frame counting unit is designed using
necessary electronic components and PCB board using
KiCad software package.The unit is mounted onto the
design with 3d printed case.
Conclusions:

19. THANK YOU