Kranes lifting device

Team Members: James Slee, Patrick Vega, Luke Rumming and Mijan Uddin.

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CONTENTS

Heading: Page Number: 1 Introduction, 3

2 Research, 4-7

2.1 Survey, 4

2.2 Mind-Mapping, 5

2.3 Existing Product Research, 6-7

2.4 Material Research, 8-10

3 Generating Ideas & Concept Sketches, 11-12

4 Concept Evaluation, 13-14

4.1 Development, 15-17

5 Conclusion, 18

6 Final Design, 19

6.1 Finite Element Analysis, 20-22

6.2 Manufacturing Process, 22

7 Reference, 23

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Introduction

There is an increasing problem of DIY workers sustaining injuries due to heavy lifting. This has been a concern as injury can make their jobs harder or impossible to complete. As a group of designers we have seen a niche in the market and believe it has been worth developing ideas that will resolve their current situation. We will design and evaluate a lifting apparatus that will hoist their products, move it indefinitely and stow away comfortably in their vehicle whilst being portable.

The final design will have three views; fully assembled view, packed view and exploded view. Documentation will be included on how each of the parts works when it is being assembled. Research of current designs and design concepts are also included. As well as, material research used to determine what the device will be made of, why these materials have been chosen and cost implications that need to be taken into account. Also there will be discussion of how this idea meets the criteria given in our design brief. This device will be the solution to builders, DIY enthusiasts and general people to avoiding injury due to heavy lifting.

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Research

Survey

Does a lifting device benefit your business?

How much would you pay for the device?

Data collected:

There was a total of twenty businesses that particpated in the survey above. The data has been collected and is represented below.

The twenty businesses were selected randomly to represent the industrial sector. The benefit data shows that 70% of businesses saw fit purpose of the lifting device and 30% saw no need of such a device. Regardless whether the businesses would have found it beneficial or not they needed to respond with their views on the products pricing. The final data for purchasing showed that 40% would pay £50 - £99.99, 50% would pay £100 - £149.99 and the last 10% would be happy to spend over £150 for the device.

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YesNo

£50 – £99.99

£100 – £149.99£150 +

Number of businesses

How much would you pay for the

Number of businesses

Does a lifting device benefit your business?

Mind Mapping

This mind map was created to aid the research that was conducted. Certain areas such as materials, method of lifting, existing products and mobility etc. were set to conduct research on. Material is an important part of the design process. There are many materials that can be used such as metals, alloys and polymers. When looking at these groups further it can be seen that for polymers there are many types of polymers such as; acrylics, HIPS and PVC. Another area that came up was the target market. There are a few target markets such as the elderly, DIY workers and middle aged men.

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Existing Product Research

When thinking about concepts and features to add to the lift, we will be developing new concepts but also redesigning designs currently used for other tasks and critically analyzing current models to find flaws in the market and look at individual aspects of each of the lifting devices.

Clarke ½ ton folding workshop crane

This crane is an engine winch and seems to be well suited for the design brief that we have created. Not only can it lift weights of up to ½ a ton but it is collapsible. Unfortunately even collapsed it is unwieldy and hasn’t been designed to fit fully extended into the boot of a car. (1)

Tiger premium mobile lift table

On a different track this also seems suitable lifting a sensible 150lbs, it could lift goods easily to the height of a car boot. Unlike the crane it adds another issue that after lifting it is at the car level. It still needs to be pushed into the car heightening the risk of snags and tears. (2)

Manual crate wizard

As a device for moving crates around this has a simple design and is proven to work in many environments. The cars ‘lip’ could prove tricky for the device to maneuver unlike the crane. (3)

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The Pacific Porta Lift Trolley

Although smaller than the other devices researched it can lift up to 100kg which is a respectable weight for its size. It’s a solid design and looks durable however the same issues remains in that it doesn’t directly place the object in the area like a crane would. (4)

Portable Ergonomic Lifting Devices

This design is similar to the others running on a basic forklift idea however this is battery powered; it also has an aluminium frame which would balance out the weight. (5)

Conclusion (Research):

What we can see from these current designs is that they are successful designs that have gotten to and beyond production stage to become successful products of their own. All of these devices have been catered to deal with specific situations. Whilst none of these are specifically catered for our situation we can take elements from these to inspire concepts and designs. As a team we have used the research to analyze parts of the current products that we believe to be successful and think makes a good product to incorporate into our first set of concept sketches.

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Materials Research

8500 Series Sky Hooks with Tool Holder Base:

This is an example of a winch system that we feel is successful, it is worth analyzing the materials and process used so we can design similar or better design and materials.

Steel roller mechanism for the cable. 2000 lbs. tensile strength roller chain. Aluminium hand wheel (8” giving 11:1 lifting advantage) Load limit of 500 lbs. >>> 226.796 kg. 4:1 ratio gearbox Structural ‘DOM’ (drawn over mandrel) tubing, lightweight steel framework DOM tube being constructed, starting as ERW and then being drawn over a mandrel.

The manufacturing process for DOM tubing begins with coils of steel, which are slit to the proper width for the desired tube size. The strip is cold formed and passed through an electric resistance welder which joins the edges together, under pressure, to complete the tubular shape. After testing the weld's integrity, the tubing is cut to length for further processing.

Strong and well-finished DOM is an electric resistance welded tube tested for soundness of weld and drawn through a die and over a mandrel. This process imparts significantly improved mechanical properties to the tube, due to the cold working process. It is considered a high quality tube, and is normally constructed from SAE 1020 or 1026 steel. Note that, technically DOM refers to the process by which the tube is finished after having started as an ERW tube. Technically, DOM is not a type of steel tube, but rather a process. ((6) refers to everything on this page)

The two graphs above are stress vs. strain graphs. The one on the left shows a comparison between fiber materials, composite materials and matrix materials.

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Facts and figures for Fiber-glass and Carbon-fiber:

(8)

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Large carbon fibre

tubes.

This is a sample of fiber glass tubing that can be purchased from a supplier.Below are figures relating to its mechanical properties.

This is a sample of carbon fiber tubing that can also be purchased from a supplier.Below are figures relating to its mechanical properties.Carbon fiber is an alternative to fiber glass but the disadvantage compared to fiber glass is the price as it is very expensive.

(8)

(8)

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(8)

Conclusion (Materials Research):

Fibreglass has been chosen as the primary material due to its excellent mechanical properties. This material will be used to construct the majority of the structure such as the cylindrical middle section.

The sample of fibreglass inspected has an ultimate tensile strength of 170 MPa which is fairly high thus making it suitable as it may need to withstand a heavy load. This sample also had a young’s modulus of 17 GPa at 90°, this is fairly impressive as a similar sample of carbon fibre has a young’s modulus of 19 GPa at 90°. This property makes it suitable as it is fairly elastic in the form of deformation thus making it less brittle, this eliminates brittle fractures. This is important as it is unsafe if there is a brittle fracture during a heavy load. The chances of seeing the defect or damage is small therefore making it sudden. If the part does fail in the form of elastic deformation it can be noticed at an earlier stage, this allows the part to be marked unsuitable for use. This material has a flexural strength of 170 MPa which gives it the same benefits as from having a high young’s modulus. The density of this specimen is 1.8 g/cc which is higher than the alternative carbon fibre which is 1.6 g/cc.

Fibreglass will also be used for the lifting arm at the top of the machine. This part must be designed very well to handle a load. This is because the other parts made out of fibreglass are in a cylindrical form which is very strong for its application.

Fibreglass tubes can be purchased at a very low price especially if bought in bulk. This is a much better option than manufacturing a cylindrical shape as this is fairly complex, time consuming and expensive.

High carbon steel will be used for the base due to its high strength. Steel is fairly heavy so the design of the base is important to maintain structural strength while trying to reduce weight.

The heavier material will be strategically used for the lower parts to counter balance the weight the machine may lift.

The castors will be made of polyurethane on aluminium wheels. Polyurethane has been chosen as it is extremely durable and does not mark the floor. These castors can be liquid cast, therefore allowing colour to be added enhancing the aesthetics.

The advantages of aluminium are as follows; Does not easily corrode Easy to work with Lightweight Strong

The advantages of fiberglass are as follows; Corrosion resistance Lightweight Low maintenance Strong

All above factors allow the device to comply with the PDS.

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Generating Ideas and concept sketches

Initially before coming up with design ideas, researching all existing products was necessary which can be seen in the research segment. A unique concept needed to be generated to fulfill the design requirements. The key points that needed to be considered when researching existing products were; must be able to lift the consumers required weight and it needed to be manually operated. There are various existing designs already on the market and none fulfill our PDS criteria.

Generating initial designs was the next step forward, most of the ideas have been derived from existing products solely because they were good to adapt to the criteria that has been outlined. Here are the eight concepts that were generated:

Concept One: Concept Two:

Concept Three: Concept Four:

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Concept Five: Concept Six:

Concept Seven: Concept Eight:

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Concept Evaluation

Feasibility evaluation:

Eight concepts have been designed to meet customer needs. To quickly eliminate any concepts that don’t meet the criteria, the use of a Feasibility Evaluation Table was created. The Feasibility Evaluation Table allows the design team to quickly discard any concept that isn’t either; an original concept, meets customer requirements or technologically feasible.

Feasibility Evaluation Table

Concept Number

Is the idea original? Does it meet customer's requirements?

Is it technologically feasible?

Worth considering?

1 YES YES YES YES2 YES YES YES YES3 YES YES YES YES4 YES YES YES YES5 YES NO YES NO6 YES NO YES NO7 YES NO YES NO8 YES NO YES NO

In this case, as a group, it was decided that: Concept five, six, seven and eight were not worth considering because they don’t meet the criteria specifications.

Concept evaluation (screening):

The next stage is to evaluate the concepts further; the Pugh concept selection method is a common structural technique used to narrow the choice of design concepts, which uses a matrices filled with criteria from the design brief and PDS. For each criterion the team marked whether the concept is worse (-), better (+) or even (s) as the datum.

Concept Screening

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Concept one was chosen to be the datum, as the design team proposed it to be the weakest link. The team then selected a concept to be evaluated. Analysing the data showed:

Concept 2 scored the highest, with its main strength being the use of space and weakness being the difficulty in handling load.

Concept 3 scored the second highest, with its main strength in efficiency and weakness in manufacturing of the product.

Concept 1 scored the lowest, with no main strengths.

The design team decided not to consider the datum and concept one for further evaluation because of the low scores it achieved in the Concept Screening Evaluation stage.

Concept Evaluation Scoring (round one):

Once all concepts have been evaluated, a more accurate matrix is implemented. Concept Scoring is a detailed weighted rating method, with the criteria rated as a percentage chosen by the design team. For the criteria, the design team graded the cost at 20% as specified in the design brief. Also, mobility, ease of use, load handling, use of space and installation were graded at 10%, with maintenance, efficiency and manufacturing graded at a respectable 5%. Each concept was then rated from 0 to 5, 0 being poor and 5 being excellent. Each concept is then multiplied by its respective weight; this produces an overall rating for each concept.

Concept Scoring Table (Round One)

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Concept 3Selection Criteria Weight Rating Weighted score Rating Weighted ScoreMobility 10% 1 0.1 3 0.3Ease of use 10% 3 0.3 1 0.1Manufacturing 5% 1 0.05 5 0.25Cost 20% 1 0.2 5 1Maintenance 5% 1 0.05 4 0.2Efficency 5% 4 0.2 1 0.05Load Handling 10% 5 0.5 1 0.1Max Load 15% 5 0.75 1 0.15Use of Space 10% 1 0.1 5 0.5Installation 10% 1 0.1 5 0.5Total ScoreRank 2 1

ConceptsConcepts 2

2.35 3.15

Development

Once the first round of the concept scoring was completed, the design team highlighted and discussed each criterion. Then strengthened the positives and reduced the negatives of each concept through synthesis and new ideas, for evaluation in round two.

For concept 2 these were:1. Ease of use.2. Efficiency.3. Load handing.4. Max load.

For concept 3 these were1. Mobility.2. Manufacturing.3. Cost.4. Maintenance.5. Use of space. 6. Installation.

Concept Two:‘Ease of Use’ was discussed and ideas were developed that can help improve the score it achieved in the first round of Evaluation Scoring. The Design team decided to take the idea of a wrench type lift from concept 3 and implement it into concept 2. This will make it much easier for the user because the motion is vertical, unlike the turning wheel that is horizontal, which can be difficult with heavy load. Further research identified a useful device that works like a pulley system called a sky hook, which works to an 11:1 ratio.

‘Efficiency’, ‘Load Handing’ and ‘Max Load’ all come under the same criteria, as they are all to do with balance. If the machines centroid is in the center then max weight can be achieved without favoring one side. If not, this can be dangerous as the machine would lean to one side and topple over, causing damage to the machine and its load. In the worst case, the machine topples over, crushing the user and anyone in the same area. The design group came up with many solutions, such as; having the center pole angled, so when the load is lifted the weight will be at its centroid. This will give the machine more balance. Another solution was to have three extendable legs that the user can change deciding on the weight of the load that needs to be lifted. The design team then decided to include extendable legs into the design, as there are many benefits for choosing this solution; this is a successful solution as the user can leave the legs on one setting for quicker and easier use.

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Concept Three:‘Use of Space’ and ‘Installation’ was discussed as one criteria and the team thought up ideas that can be improved for this concept. The whole machine is complex, due to a large number of nuts and bolts needed to be inserted before use. Therefore, getting the machine ready for use will take the user a long period of time, and this won’t be productive for our target market. The design team tackled this problem by removing nuts & bolts that are not deemed necessary. This then made the machine much easier and quicker to install. Therefore ‘Manufacturing’, ‘Cost’ and ‘Maintenance’ will be reduced as there aren’t as many holes and parts needed to be drilled and manufactured providing a much more simple manufacturing process.‘Mobility’ was discussed as a group and a member was assigned to research different solutions to tackle this problem. A three legged design is guaranteed to be stable, because the ends of its legs always form a plan, and a four legged design will due to its center of gravity being further inside its base. It was then decided to implement the leg design from concept 2 into concept 3, giving the design a much more steady foundation and increasing its mobility.

Concept Two & Three:

Here you can see the evolution of our chosen arm for concept two and three, as it can be seen in picture 1 the arm started as a collapsible wire based design which had several removable pins to help it to go as flat as possible. However after discussion it was decided that keeping it as a single piece would keep the product stronger as a whole.

From figure 2 and 3 you can see a design similar to that

of the final however it is more rounded and is larger than necessary. It is also open to the elements unlike the final meaning that it is possible and likely for the wire and the rollers to get rusty.

The final design for the top arm is figure 4 this uses a chain instead of wire so that the device has a better control and grip over a weighted chain. It is angular and completely covered along with being thinner it a more aesthetically pleasing design.

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Concept evaluation scoring (round two):

The design group then sketched each concept with its new solutions and applied the Pugh concept with concept 2 being the datum. The results were then analyzed and concept 2 being the datum (as It received the highest score in round one) was scored higher then concept 3. The design group then decided to go with concept 2 for further development.

Concept Scoring (Round Two)

Conclusion of evaluation:

By choosing concept 2 the design team believes that the product succeeds on points such as space and ease of use. All team members understand why this solution is the best, and all are committed to this concept which is now ready for prototyping

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Concept 3Selection Criteria Weight Rating Weighted score Rating Weighted ScoreMobility 10% 3 0.3 3 0.3Ease of use 10% 3 0.3 4 0.4Manufacturing 5% 3 0.15 5 0.25Cost 20% 3 0.6 5 1Maintenance 5% 3 0.15 4 0.2Efficency 5% 4 0.2 4 0.2Load Handling 10% 5 0.5 4 0.4Max Load 15% 5 0.75 4 0.6Use of Space 10% 4 0.4 5 0.5Installation 10% 3 0.3 5 0.5Total ScoreRankContinue

2 1No Develop

ConceptsConcepts 2

3.65 4.35

Conclusion

The aim was to come up with a design that will lift a required amount that is portable from point A to point B and to stow away in to the user’s vehicle. In this report, a device for DIY workers to lift what they need has been designed and the following occurred: There was hesitance when deciding between the two ideas. Concept 2 was ideal for the consumers’ needs and come to score higher than the other idea because it was noticed to be more adaptable to comply with the PDS. Concept 3 was seen to be close to being a complete design but issue arose such as: size, weight of the equipment and cost of manufacture. Therefore Concept 3 was eliminated due to those reasons. Concept 2 was modified to become smaller so it can be stowed away and a three wheeled base came to be more stable than four. The wrench component from Concept 3 was transferred to Concept 2 because it was shown to be very easy to use and efficient. Fiberglass was chosen as the primary material followed by aluminium as the secondary material. Fiberglass was chosen as the primary material as it has excellent mechanical properties which are suitable for our purpose. Fiberglass can also be bought in bulk in a tubular shape therefore lowering expenses and reducing manufacturing. Ease of use and ergonomics has always been considered throughout the design process. The design that was selected meets our aims and has gone through development now complies with the criteria of the PDS.

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The Final Design

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Finite analysis

Finite element analysis was carried out to prove that the machine can lift the required load if a safe manor. It was also done to ensure that the machine can withstand the load that may be applied without any damage occurring. Throughout the analysis (see pictures above) it is clearly visible that there very little parts that undergo very high stress and strain. High levels of this can be seen by the color red. The only red part is the base where there main lifting arm connects to. This is prone to experience high levels of stress and strain is this is the part that connects the main lifting arm to the rest of the body. The rest of the body colored in purple is experiencing very little stress and strain. This is due to the structure and shape of design.The arm is made of aluminium, which takes the maximum load that needs to be lifted. Through finite analysis it shows that the arm will be able to take the load without

breaking but, it does show deformation caused by the load. The joint is used to attach the arm to the beam which is also made out of aluminium. It under takes a moment caused by the load on the arm the analysis shows that there is no breakage on the holes. Fiberglass is used

to make the beam. Analysis was undertaken on each of the holes; Top, Middle and Bottom and it showed that the beam will be able to take the maximum load.

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This is the culmination of the analysis and decision processes, it is a collapsible and multi directional lifting device with a gear based winch.

The device can lift up to 200 kilos carry it around easily and lower it on a chain based winch from 0m to 2m in the air.

The gear based winch makes it easy and reliable to lift heavy objects with minimal effort to the user.

The handles also make it easy to move a loaded device about and rotate the top arm these both are at convenient heights and can be adjusted with whichever height was chosen in the lower tube.The body handle is attached to the bolt that holds the upper and lower tubes together.

The three retractable legs make it easy to get objects close to the lifting arms body. The legs can also be shortened if the object carried needs to be closer to where it needs to be lowered.

The device can be seen folded up on the left, the inner tube slides down into the outer and the legs retract into themselves making the device considerably more compact for either storage or moving objects in smaller spaces.

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Arm, Stress Maximum Principle

Arm joint to beam, Stress Maximum Principle

Beam, Load acting at the top, Stress Maximum Principle

Load

Manufacturing processAs explained earlier the bulk of the design will be constructed out of fiberglass and aluminium in an effort to minimize weight. The majority of the design has been pre manufactured so that the manufacturing process is as quick as possible. The main body of the device is made out of fiberglass tubes which would be bought in and have the holes drilled into them. The bolts, handles and wheels would also be bought in along with the chain as these are mass produced and to standard so it would be unnecessary and expensive to produce ourselves.

The top arm and the legs would have to be produced ourselves by using a milling process. Whilst this is a slightly wasteful method it will result in a genuinely stronger product which can handle the repetitive stress strain placed upon it.

Firstly it would be in our best interests to build a prototype before going into mass production, we would go about this by buying all the mass produced parts needed from the appropriate sources. In the future we will be buying them from wholesalers or from the source so that we have smaller costs for buying in goods in bulk. For the aluminium bars we

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Beam, Load acting in the middle, Stress Maximum Principle

Beam, Load acting at the bottom, Stress Maximum Principle

would also do the same taking the upfront costs on ourselves. However we would only be renting a CNC machine for a small time from either a small business or a university so we can have a working prototype. The next step would be to rent a factory space and all the devices needed to hit our first production targets.

References

1. http://www.clarketooling.co.uk/tools/Workshop_Cranes___Engine_Stands.html2. http://www.midlandpallettrucks.com/midland-pallet-trucks-products.asp?c=21073. http://www.simpro.net.nz/products/manual-crate-wizard, 20124. http://www.pacifichoists.com.au/our-products/categories/materials-handling-

equipment/trolleys-trucks/pacific-porta-lift-trolley/, 20135. http://www.ergonomicpartners.com/Portable-Ergonomic-Lifters.aspx , 20136. http://www.skyhook.cc/model8500.html, Syclone attco service, 20127. http://www.ecfibreglasssupplies.co.uk/p-659-polyester-glassfibre-tube-254mm-x-

194mm.aspx8. http://www.ecfibreglasssupplies.co.uk/p-659-polyester-glassfibre-tube-254mm-x-

194mm.aspx

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Design Brief

Business name: JPLM

Contact number: +1 650 253 0000

Due date for completion: 4/12/2013

Review date/s: 3/12/2013

Budget: £20,000.

Product/service/brand name: Kranes.

Key objectives:

Innovative idea. Low manufacturing cost. Quick and cheap to mass-produce. Low maintenance. Easy installation. Highly mobile. Aesthetically pleasing. High max load. Highly efficient.

Marketing objectives and target audience:

The target audience will be aimed at males averaging an age of 20-50. With an occupation such as: builder, self-employed, painter, engineer or carpenter. A survey was constructed to see whether local builders and painters would find a product like this useful for their business. The results were unanimous; every person that took the survey believed that a product like this would be useful for their business taking the strain off their workers.

The main advertising tools will be the Internet and Local Newspapers. Internet will be the

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main advertising tool because of its great cost effective way of advertising a product worldwide. When analyzing the results from the survey, it revealed that a large percentage of the target market use sites such as YouTube and Facebook to promote their business in some way. So by using the same sites to advertise our product will then ensure the right marketing methods are being applied for optimum promotions.

Local Newspapers will be a great way to advertise as the target market will also be advertising their business through the same method.

Sales promotional plans such as:

Frequent shopper card- offer the customer discount after they have made a specific number of purchases.

Have a sale- giving discount to all customers. Hold a contest- offer to automatically entering into a contest. Offer free shipping- if the customer is within the United Kingdom. Discount to target market- enabling the target market discount.

Direct Marketing/advertising plans such as:

Posters, banners and signs- place these in retail stores and display them in private business where people gather.

Brochures Newsletters- enable the business to communicate regular with potential customers. Hiring of ad agency or marketing firm Outdoor advertising- billboards and signs.

Publicity plans such as:

Sponsor an event Put on an in-house event Attend trade shows Create a blog Host an event

Distribution will be achieved by the use of Lorries for internal delivers and shipping containers for external delivers.

Scope:

This specification will deliver aspects such as:

Portable- allowing the user to travel with the design. Takes up minimal amount of space- giving the customer maximum room for the

goods. Low maintenance- long part lifetime Easy installation- easily installed and easily dismantled

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High max lift- being able to lift heavy bulky goods. Aesthetically pleasing- unique designs makes the Product stand out from other

competition.

Purpose and function:

The purpose of this design is to enable easy lifting of heavy bulky goods. The design needs to be portable, fit into a domestic vehicle and still be able to lift several objects at one time. The target market is aimed at builders, painters and self-employed that are from the ages of 20-50 who are hoping to take the strain of heavy lifting off their body, realizing they need a solution, but don’t want /cannot afford to employ a worker. This is where a machine would be the best solution as it’s a one-off-payment but also performing most of the workers needs. Unlike employing someone that you have to pay a respectable daily wage, allocate lunch times, sicknesses and holidays.

Regulatory issues:

Article 69 of EU BPR. Regulation 31 of UK BPR. Supply of Machinery (Safety) Regulations 2008. CE Marking. Instructions. Declaration of Conformity.

Format:

Pro Engineer Creo Parametric 2.0 Sketches

Design Project plan:

Task Number Task Team leader

1. Target Market Research Luke

2. Existing Product Research

Mijan

3. Material Research James

4. Generating Ideas & Concepts

Patrick

5. Concept Evaluation Luke

6. Conclusion Mijan

7. Finite Analysis James

8. Manufacturing Process Patrick

9. Design Brief Luke

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10. PDS Mijan

Measures of success:

The way in which this design will be successful is choosing the right target market. As mentioned earlier the survey suggests that the products would be helpful and useful for their businesses. This information clarifies that the design brief meets the correct target market.

A detailed drawing will be constructed to show the design in a three dimensional view. Finite Analysis will be run to prove that the design can lift its maximum weight, without causing any major stress to the weaker points.

Product Design Specification

Contents1 Introduction2 Scope3 Standards and specifications adhered toMain4 Performance5 Environment6 Ergonomics7 Aesthetics8 Size & weight9 Restrictions / limits10 Quality and reliability

11 Manufacturing12 Testing13 Company constraints14 Process15 Packaging16 Shipping

17 Installation / fitting / setup18 Maintenance19 Service life20 Product life span21 Shelf life22 Safety

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23 Legal24 Documentation25 Disposal

26 Target audience27 Marketing28 Competition29 Costs30 Quantity

31 Bibliography

1 IntroductionTo design a general and multi-purpose lifting device to sell in the trade of construction, DIY

and possibly the automotive repair sector.2 Scope

The specification will deliver aspects such as: portable, easy to store, takes up minimal amount of space, low maintenance, pleasing to the eye, fashionable, easy installation and high max lift.

3 Standards and specifications adhered to Article 69 of EU BPR. Regulation 31 of UK BPR. Supply of Machinery (safety) Regulations 2008. CE Marketing. Instructions. Declaration of Conformity.

4 Performance Lift and lower a load of 200kg (+/- 10%). Wrench component must not lift if the load exceeds 10% of the specified load. Wrench component must stop lowering when only 1 metre of the cable remains on

the winch drum. Wrench component must operate with wind and unwind. The product must lift 2.0m in the air. The product must be portable. The product must be man powered. The weight of the product must be sufficient to aid the stability of the product. The drum must hold 5m of cable.

5 Environment Temperature ranges; -25 degree C – Europe, 10-45 degree C – Far East. The product will experience all weather conditions. Corrosion resistance must be considered by use of special materials or surface

protection methods.

6 Ergonomics

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Controls to be mounted in an accessible position, relative to the operator i.e. waist height - around 1m, to accommodate 95% of the working population.

All controls should be hand operated. One man should be able to operate the product.

7 Aesthetics The form can follow function.

8 Size & weight Weight must not exceed 20kg. Width must not exceed 900mm. Height must not exceed 1800mm

9 Restrictions / limits Lift and lower a load of 200kg (+/- 10%).

10 Quality and reliability Quality must be such that the wrench component must not generally fail within a

period of three years and only 1 in 50 should fail within the first year. The wrench component must not fail in the area of the safety overload device.

11 Manufacturing Capacity is available for current market demand within scope to increase production

to 200 per year without investment / expansion.

12 Testing Testing is to be carried out on 20% of units.

13 Company constraints

These include constraints/limits outlined in the manufacturing process.

14 Process All components to be of metric form and comply with BS4500 (1) for limits and fits.

15 Packaging Packaging / transport cost should be kept to a minimum and preferably below 5% of

the unit cost.

16 Shipping

Distribution will be achieved by the use of lorries and shipping containers for internal deliveries.

Product will be shipped by road within Europe. Product will be shipped by sea to Far Eastern markets.

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17 Installation / fitting / setup The product will be very simple to set up as there will be minimal separable parts.

These parts consist of the base, the centre section, the winch mechanism and the lever.

18 Maintenance To be maintenance frees except for light lubrication once a month and a

recommended service every two years. Parts requiring lubrication should be accessible within 15 minutes without the use of

special tools or equipment. All fasteners used should comply with BS6105(2)

Spares should be available for 5 years after the product is replaced with a new model.

No special tools should be required for maintenance.

19 Service life Should withstand an operating period of 1 hour uninterrupted use per day for 5

years. Life in service should be assessed against the criteria outlined in the Performance

and Environment categories.

20 Product life span The product will be on the market for 10 years. Spare parts will be available for an additional 5 years.

21 Shelf life

The product will be stored on-site for up to 1 month before dispatched. Our Far East distributor may store the product for several months.

22 Safety The wrench component must not fail in the area of the safety overload device. The wrench component must not operate when maintenance is being carried out.

23 Legal Possible litigation lies in the user injuring themselves by having access to moving

parts during winch operation.

24 Documentation Product must be supplied with a user manual covering winch operation and

maintenance. Suppliers require maintenance and repair manual.

25 Disposal Plastic parts must be separable and marked to aid disposal.

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26 Target audience The target audience will mainly be aimed at males averaging an age of 30, with an

occupation such as and builder, self-employed, painter, engineer or carpenter.27 Marketing

The main advertisement tools are the internet, newspapers, building events and DIY programmes. The internet will be the main advertising tool because of its great cost effective way of advertising a product internationally. A great promotional plan would be to join forces with a large supplier such as B&Q. This would boost our sales, as they have thousands of stores worldwide and are known as a reliable company.

Initially to be manufactured for the European market but our Far Eastern distributors in Singapore, Hong Kong and Australia will be able to find a market for the product.

Applicable markets: Telecom - Cable laying, Gas and Electricity operators, Pipe laying services, Civil Engineering Operations.

Summary of market requirements: Portable product, To be used in all weather, To allow one man operation, To have at least 10m of cable, To pull 200kg.

28 Competition

The competition will be against equivalent models from countries such: USA and Germany etc. Other competition may possibly arise in the UK from companies such as B&Q and Wickes as these companies are known to create their own equivalent model or whatever the market already has. These companies usually rebrand the product by using its generic name.

29 Costs

The product should have an end-user cost of less than £150 within Britain. The cost of manufacture should be less than £500. The cost of packaging and shipping should be no more than 15% of the

manufacturing cost.

A single prototypeMaterial cost for prototype: £290Manufacturing labour for prototype: £200Overhead costs (8 week schedule for 1 prototype): £4,320Rent: 500 p/wUtility bills: 40 p/wSalary for 4 members over 8 weeks (CAD engineer, researcher, designer, lead designer): £15,500Miscellaneous costs: £100Grand total for produce a single prototype over 8 weeks: £20,410

Expenditure over 1 year

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(this is by assuming that 3 units will be made a day and also considering a decrease in material and manufacturing labour costs as bulk material will be purchased and workload does not increase with units made)Material cost: £71,000 p/a (£19 per unit)Manufacturing labour: £54,000 p/a (£200 per day for 10 units)Packaging and shipping: £37,000 p/a (£10 per unit)Overhead costs: £29,160 p/aSalary for 4 members: £105,000 p/aGrand total to manufacture and distribute 10 units a day over 1 year: £296,160Each unit costs £78 throughout the whole process, selling it for £128 per unit gives £50 profit per unit totalling £189,000 profit per year.

30 Quantity 3780 units in the first year, increasing to 7560 within three years

31 Bibliography

1 http://www.bath.ac.uk/idmrc/themes/projects/delores/co-design-website/dpg/tol/tol2.html 20112 http://www.bssa.org.uk/topics.php?article=1 (Home/ Technical Help/ Technical Library /Standards, Specifications & Grades/ BS/BSEN Grades Compositions Properties)

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