1. COMPACT MOBILE LIFTING DEVICE Team 99.03 Michael Shaffer, Ken Kammerer, Dave Geesaman, Jin Ko Sponsor: Jim Adkins, Fraunhofer Advisor: Dr. Michael Keefe Innovative Lifting Solutions

2. Hot Press Thermal Technology Inc. Loaded / Unloaded daily

3. Injection Molding Machine Arburg AllRounder S-Series Loaded/Unloaded roughly once per month

4. 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 and a hot press. Approach: After examining existing positioning, transporting, and lifting methods, we designed a custom system which met the unique wants and constraints at Fraunhofer.

5. Customers James Adkins Lab Coordinator Don Kupp Supervisor Michelle Mattera Lab Technician Brandon Fichera Lab Technician Bernie McGuinness Lab Technician Thermal Technologies, Inc. Equipment Manufacturer Arburg Manufacturing Equipment Manufacturer Bishamon Lift Manufacturer

6. Wants  Versatility46%  Fast Operation35%  Minimal the amount of manual lifting 17%  Easily Maneuverable13%  Minimal Reaction Forces on Machines 7%  Low Prototype Cost5%  Low Cost of Manufacture2%  Low Maintenance Cost1% DescriptionRelative emphasis

7. Constraints load the objects without failure fit in working areas adjacent to machines maneuver through doors, hallways on premises reach injection molder at 46” (max. height) reach mold storage rack at 26” (min. height) have safety locks on all moving parts be operable by a single user withstand use in a commercial situation not damage objects being manipulated Our Solution must...

8. Versatile: Primary Wants and their Metrics Fast operation: Maneuverable: Interfaces with all devices (Target: Yes) Minimize forces on Machines: Forces (Target: 0 pounds) Minimal Lifting: Power input by user (Target: 0 H.P.) Time to load & unload (Target: 15 minutes) Time to convert between modes of operation (Target: 0 sec) Pushing forces (Target: 20 pounds) Overall weight (Target: 400 pounds)

9. Primary Wants and their Metrics Minimize cost of Manufacture: No. of standardized parts (Target: All) 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)

10. Top Six Metrics Time to convert between modes12.8% Number of Commercially available parts10.6% Time to move object into position9.2% Power input by user8.5% Number of machines device can interface with7.8% Overall weight6.4% DescriptionRelative Emphasis

11. Benchmarking Devices Lift carts Chain Hoists Drawer Slides Linear Bearing Systems Key Points Lifting Maneuvering Swiftness Low user effort Commercially available Compact

12. Concept Generation Interface with both machines: Fork system Lifting: Scissors lift, fork lift, hoists Maneuverability: Caster wheels, air cushion Positioning: Drawer slides, linear bearings, UHMWP

13. Concept 1 : Sliding Forklift Strengths: Forks provide versatility Time to convert is low Commercially available parts Drawer slides / linear rails allow positioning Hydraulic lift cart provides lifting and mobility via caster wheels

14. Concept 2 : Fold - out Low - Friction Tabletop Strengths: Versatile Commercially available parts Fast positioning via UHMWP Hydraulic lift cart provides lifting and mobility via caster wheels

15. Final Concept: Hybrid 1) Mobility: Caster Wheels Low cost, commercially available, adequate maneuverability 2) Lifting: Hydraulic Scissors Lift Precise height control, good extension / overall size ratio 3) Positioning: Modular Fork Low-Friction Platform Linear Bearings Modular design offers compatibility with current and future applications Concept Selection

16. Analysis / Theory Elastic Solid Mechanics, Static Analysis Design Criteria: Deflection Stress-life Design Bearing Design Analysis Methods: Beam Model with Stress Concentration Factors Beam Model using TK Solver Finite Element Analysis (COSMOS/Works)

17. Prototype Commercially Purchased Parts: Bishamon LPM-50 Lift Table Thomson DB Series Linear Rails Screw - down clamps (locks) Custom Machined Parts: Structural Forks and Platforms (6061-T6 Aluminum) Low-Friction Sheeting (UHMW Polyethylene) Assembly: Allen Cap Screws, Flat-head Machine Screws, nuts, washers Dowel Pins

18. Testing and Results Interfacing with all machines and molds Deflections of loaded members and assembly Stability / Tipping forces Conversion time Loading and unloading time Maneuverability Forces required by user for operation Wheel locks found insufficient Cart not level

19. Budget Fraunhofer Project Budget Goal: $3000 Off-the-Shelf or Commercially Available items · Hydraulic scissors lift cart$795 · Linear bearings$1156 · Fasteners (nuts, bolts, washers, etc.)$100 Raw Materials · Aluminum Stock$190 Wooden Model$60 Machining Time (33 hours)$0 Engineering Development (400 hours)$0 Miscellaneous $90 TOTAL:$2391

20. Recommendations: Forks made from alternative materials Additional fork(s) for interfacing with future machines Improved wheel locking system Motorization and control of lifting and positioning Accessories bin for on-board parts storage