COMPACT MOBILE LIFTING DEVICE Team 3 Michael Shaffer, Ken Kammerer, Dave Geesaman, Jin Ko Sponsor: Fraunhofer Advisor: Dr. Michael Keefe Innovative Lifting Solutions

Background and Problem Description Mission & Approach Customers, Wants, Constraints Metrics, Target Values System Benchmarks, Functional Benchmarks Concept Generation - Derivation from Critical Functions Concept Development Concept Selection - Evaluation against Metrics Working Model Schedule Budget Summary

Fraunhofer has three machines which utilize molds to process plastics and metals. The molds are heavy and large, making it difficult for a person to install and remove them from the machines. They desire a device which will provide mechanical help in transporting these heavy objects.

Hot Press Thermal Technology Inc. Loaded / Unloaded daily

Injection Molding Machine Arburg AllRounder S-Series

Injection Mold Storage Rack Lowest Operating Height: 25 to 30 inches; adjustable

Vacuum Oven Centorr Vacuum Industries Highest Operating Height: 52 inches; fixed

Approach: We will use the engineering method to obtain a conceptual design based upon the wants and constraints of the customers. From this we will construct and test a prototype in order to obtain our final product. Mission and Approach Mission: To design and build a mobile device which will aid a user in lifting, moving, and placing heavy molds into an injection molding machine, a hot press, and a vacuum oven.

Customers Users of the device James Adkins Michelle Mattera Brandon Fichera Bernie McGuinness Molding Equipment Manuf. Centorr Industries Thermal Technologies, Inc. Arburg Manufacturing Commercial Manufacturers Wesco Bishamon Lee Engineering Centorr Industries Thermal Technologies Arburg Manufacturing

Wants  Versatility  Minimize Time for Operation  Maneuverable  Minimize Forces on Machines  Minimize the wear on objects  Inexpensive Prototype  Minimize Cost of Manufacture  Minimize Maintenance Cost

Constraints Must fit in front of the machines it needs to interface with Must fit through doors at Fraunhofer Must roll on tile floors Must reach highest machine at 53” (max. height) Must reach mold rack at 26” (min. height) Must have provisions for locking of all mechanisms Must be operable by a single user Must withstand use in a commercial situation Must be capable of moving the objects Angle deflection of molds when supported must be less than 1  Must not damage objects being manipulated

Versatile: Primary Wants and their Metrics Fast operation: Time to load & unload (Target: 5 seconds) Maneuverable: Pushing forces (Target: 10 to 20 pounds) Overall weight (Target: 200 pounds) Time to convert between modes of operation (Target: 0 sec) Interfaces with all devices (Target: Yes) Minimize forces on Machines: Forces (Target: 0 pounds)

Primary Wants and their Metrics Minimize cost of Manufacture: No. of standardized parts (Target: All) Overall Weight (Target: 400 lb.) Minimize cost of prototype: No. of standardized parts (Target: All) Minimize cost of Maintenance: No. of standardized parts (Target: All) Cost to replace failure-sensitive components (Target: $0)

Prioritized Metrics

System Benchmark Best and Only Practice Wesco Hydraulic Lift Table and Manual Loading Caster wheels provide good maneuverability Hydraulic lift cylinder provides large lifting capacity Disassembly necessary for large molds

Functional Benchmarks Functions: Lifting and Moving Bishamon ESX40 Scissors Lift Related Metrics: Allows interface with all machines Commercially available Low number of moving parts Maneuverable Low weight (229 pounds)

Functional Benchmarks Functions: Lifting, Positioning Yale powered chain hoist Related Metrics: Commercially available Maneuverable Motor powered for minimal operator work Low positioning time

Functional Benchmarks Function: Positioning Heavy duty drawer slide Related Metrics: Low positioning time Commercially Available Inexpensive

Functional Benchmarks Function: Positioning Related Metrics: Low positioning time Commercially Available Low user force required High precision Expensive Thomson Pillow Blocks & Rails

Concept Generation 1) Investigated critical functions 2) Analyzed each function and found a particular, ideal solution 3) Pooled solutions and determined best combinations 4) Used SSD to analyze strength of each concept

Concept Generation Top Critical Function: Interface with all three machines Concept must allow handling of differently shaped objects: Cubical injection molds Cylindrical hot press molds Flat plates for Vacuum oven Concept of fork design makes use of flat bottom commonality between all three objects

Concept Generation Other Critical Functions used in Concept Generation: Lifting - Scissors Lift & Hydraulic Lift Mobility - Caster Wheels & Air Cushion Positioning - Drawer Slides & UHMWP

Concept 1: Sliding Forklift Strengths: Time to convert is low Uses commercially available parts Can interface with all three machines Low conversion time Forks provide versatility Drawer slides allow positioning Scissors lift provides lifting and mobility via caster wheels

Concept 2: Fold-out Low-Friction Tabletop Strengths Uses commercially available parts Can interface with all three machines Fast positioning Utilizes UHMWP for quick and low-effort positioning of objects Scissors lift provides lifting and mobility via caster wheels

Sliding Forklift Concept: Time to convert between modes of operation is low – Forks are interchangeable and held on by wing nuts – Estimated time required: 5 minutes Prototype, Mass Production, and Maintenance costs are low – Uses 70% commercially available parts – Estimated cost - $2300 Object loading and positioning – User effort is low – Estimated 5 pounds force required for positioning Weight is within acceptable limits – Estimated weight is 400 pounds – Estimated push force of 20 pounds Evaluation of Concepts Against Metrics

Low-Friction Table Top Concept: Prototype and Mass Production costs are low – Uses 80% commercially available parts – Estimated cost - $2000 Object loading and positioning – User effort is relatively high – Estimated 40 pounds force required for positioning Weight is within acceptable limits – Estimated weight is 300 pounds – Estimated push force of 15 pounds Time to convert between modes of operation is reasonably low – Fixtures for each machine provide interfacing – Estimated time required: 10 minutes

Working Model Full scale wooden replica Critical functions to prove: Interfacing with all machines Range of lifting height Positioning system for objects 3-D rendering of Wooden Model

Schedule to date

Schedule: looking ahead

Budget Fraunhofer Project Budget Goal: $3000