A PE teacher needs to move footballs, rugby balls, bibs, and cones from the equipment store to the playing field each lesson. The teacher currently carries ...

(a) Four functional points [4 marks]

1. Separate compartments for different equipment — Footballs, rugby balls, bibs, and cones have different sizes and shapes. Mixing them in a single bin makes specific items hard to find. Dedicated sections (a cage for balls, a basket for bibs, a post or slot for stacking cones) keep equipment sorted and speed up lesson setup. [1]
2. Operable by one person with a comfortable handle — The PE teacher must be able to push or pull the fully loaded trolley alone. The handle must be at an ergonomic height (approximately 900-1000 mm from the ground) and provide a comfortable grip. The overall loaded weight should not exceed what one adult can move across grass (approximately 30-40 kg maximum). [1]
3. Wheels suitable for uneven grass — Standard small castors (50-75 mm diameter) sink into soft grass and mud. The wheels must be large enough (at least 200-250 mm diameter) with wide, pneumatic tyres that distribute load over a larger area and roll over bumps, divots, and mole hills without stalling. [1]
4. Fits through a standard doorway — The trolley must fit through the equipment room door (typically 800-900 mm wide) for indoor storage. This constrains the maximum width. A narrower profile with taller stacking compensates for the width limitation. [1]

(b) Two wheel arrangements [4 marks]

Arrangement 1 — Four pneumatic wheels with front swivel castors: Four large (250 mm diameter) pneumatic-tyred wheels are mounted at the corners. The rear pair is fixed (providing straight-line tracking), and the front pair is mounted on swivel castors (allowing steering). The pneumatic tyres absorb bumps and provide grip on wet grass. The four-corner layout gives maximum stability. The swivel castors pivot freely, allowing the trolley to be turned in tight spaces. [2]

Arrangement 2 — Two large rear wheels with single front wheel (wheelbarrow layout): Two large (300 mm diameter) pneumatic wheels on a fixed rear axle bear most of the load. A single smaller wheel at the front provides a third contact point for stability. The user tips the handle slightly to lift the front wheel for steering, similar to a wheelbarrow. The wide rear tyres prevent sinking on soft ground. This three-point contact is stable on slopes but requires the user to balance the trolley slightly when turning. [2]

(c) Three design ideas [12 marks]

Idea 1 — Tiered cart with mesh ball cage, bib basket, and cone post: A welded mild steel tube frame on four large wheels. The top tier is a mesh-sided cage (approximately 600 mm x 400 mm x 400 mm) that holds up to 10 footballs or rugby balls, with a hinged mesh lid to prevent balls bouncing out during transport. A lower basket (mesh or nylon fabric) holds bibs with ventilation for drying. A vertical post (25 mm diameter tube, 500 mm tall) at one side stacks cones over the post. A tubular push handle extends from the rear. [4]

Idea 2 — Flat-bed trolley with removable dividers and mesh sides: A flat platform (1000 mm x 500 mm) on four wheels, with mesh side panels (300 mm tall) that fold down for compact storage. Removable plywood dividers slot into channels on the platform to create adjustable compartments. This design is versatile (dividers can be repositioned for different equipment mixes) but balls tend to roll around on a flat surface and can fall over the low sides. [4]

Idea 3 — Wheelbarrow-style unit with single deep bin: A deep V-shaped bin (600 mm x 400 mm x 500 mm deep) on two large rear wheels with handles at the back. Equipment is loaded into the single bin. The deep bin prevents items from falling out. Removable internal partitions separate ball, bib, and cone sections. The wheelbarrow design requires the user to lift and balance the handles, which is more tiring over long distances with a heavy load. [4]

(d) Evaluation and justification [8 marks]

Idea 1 (Tiered cart) — Strengths: dedicated sections keep equipment organised; mesh cage prevents balls escaping; cone post is efficient; four wheels give stability; push handle at comfortable height. Weaknesses: the welded frame requires metalworking skills.

Idea 2 (Flat-bed) — Strengths: versatile; flat-folding sides for storage. Weaknesses: balls roll on the flat surface; low sides risk items falling off; removable dividers can be lost.

Idea 3 (Wheelbarrow) — Strengths: deep bin prevents items falling out; simple construction. Weaknesses: user must lift and balance handles; tiring over distance; single bin makes finding specific items difficult.

Chosen idea: Idea 1. The tiered cart with dedicated sections provides the best organisation (each equipment type in its own compartment), the mesh ball cage prevents items escaping during transport across bumpy ground, and the four-wheel design allows one-person operation without lifting or balancing. The cone post is an efficient space-saving feature. The welded mild steel frame is strong enough for daily school use and achievable in a school workshop with MIG welding equipment. [8]

(e) Full solution — construction details [12 marks]

The solution is drawn in isometric projection with a plan view showing the compartment layout and a detail of the axle mounting.

• Frame: Welded from 25 mm square-section mild steel tube. Base frame: 900 mm long x 500 mm wide (rectangular, butt-welded at corners). Four vertical uprights (700 mm tall) at the corners support the ball cage. The push handle extends 300 mm beyond the rear uprights at 900 mm height.
• Ball cage: Galvanised steel mesh panels (50 mm x 50 mm grid, 3 mm wire) welded to the upper frame section (600 mm x 400 mm x 400 mm). A hinged mesh lid prevents balls bouncing out. The mesh allows rain to drain through.
• Bib compartment: A nylon fabric basket (500 mm x 400 mm x 200 mm) is suspended from the frame rails below the ball cage using Velcro straps. The breathable fabric allows wet bibs to dry during transport. The basket is removable for washing.
• Cone post: A 25 mm diameter mild steel tube (500 mm tall) welded vertically to the frame at one corner. Cones stack over the post by their central holes.
• Wheels: Four 250 mm diameter pneumatic rubber wheels. The rear pair is mounted on a fixed axle (12 mm steel rod) running through the base frame. The front pair is mounted on swivel castors bolted to the base frame corners.
• Handle grip: A rubber bicycle handlebar grip slipped over the push handle tube for comfort.
• Overall dimensions: 1200 mm long (including handle) x 500 mm wide x 1100 mm tall.

(f) Materials [4 marks]

1. Mild steel tube (25 mm square section) for the main frame. Mild steel is strong, can be welded easily using MIG or oxy-acetylene equipment (both commonly available in school workshops), and is widely available. The square section provides flat faces for welding joints, making alignment easier than round tube. It can be painted with rust-inhibiting primer and a coloured topcoat for weather protection. [2]
2. Pneumatic rubber wheels (250 mm diameter) for the ground contact. Pneumatic tyres provide grip on wet grass (the tread pattern bites into soft ground), cushioning over bumps (reducing the risk of equipment bouncing out), and load distribution over a wide contact patch so the wheels do not sink into soft soil. The 250 mm diameter rolls over obstacles that would stop smaller wheels. [2]

(g) Manufacturing the base frame [6 marks]

1. Mark out: Mark the four base frame lengths (two at 900 mm, two at 500 mm) on 25 mm square-section mild steel tube using a scriber and steel rule. [1]
2. Cut: Cut each length using a hacksaw secured in an engineer's vice, keeping to the waste side of the scribed line. [1]
3. File: File all cut ends flat and square using a flat file, removing burrs and saw marks. Flat, square ends ensure tight butt joints at the corners. [1]
4. Set up for welding: Set the four lengths into a rectangular frame on a flat welding table. Check squareness with a try square at each corner and clamp with G-clamps or magnetic welding squares to hold the frame in position. [1]
5. Weld: Tack-weld each corner joint using MIG welding, then check alignment before completing the full weld run on each joint. Tack-welding first allows adjustments before committing to the full weld. [1]
6. Finish: Allow the frame to cool naturally (do not quench). Clean the weld beads with a wire brush to remove slag and spatter. Apply a coat of rust-inhibiting metal primer followed by a coloured topcoat of spray paint. [1]