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final design report - Southern Illinois University

1. lt lonaosd 3539041 Ad 60 PRODUCED AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 JD 2 3 B Saluki Engineering DRG NO pol l 2 OF 1 IvNOLLVOnQd3 NV Ag PRODUCED BY AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AUTODE 3 EDUCATIONAL PRODUCT 2 DRAWH Matt Lane 4 23 2011 MEE 62 TITLE dk 1 WNOLLVONGS 59901 Ag PRODUCED BY AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 a D BY AN AUTODESK EDUCATIONAL PRODUC 63 1on osd IwMNOLLvoncd3 Xsaqdolnv Ag Appendix C Lifting Mechanism 64 PRODUCED AUTODESK EDUCATIONAL PRODUCT PRODUCED AUTODESK EDUCATIONAL PRODUCT 3 2 BIN AUTODE 65 R EDL zm ONA dk DRAWN Ll HEN E S OF 2 1 WNOLLVONGSA MSS0OLNVW NV 1 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 VE 2 1 dk DRAWN iad T 7 gt _____ e l 1 3
2. ROSS 27 S35 SUD y SUC 28 28 23 02 29 2 0 9 ot ve aR 29 OS ROL ______ ____6__8____________ _ ___ 31 SOCON C T N OS evn once 37 6 0 Impl rmientatiorscehedule u 39 7 0 Conclusion 5 41 Appendix Av General Appendics 42 RETERCNCCS um MEI DIE 42 1 DMS Welding and Machine 696 Bethel Road Vergennes IL 629941408 42 Appendix B Chassi SUDSECH ON a e ee Eq aua 42 Appendix Mechiambsrm 2o ua ee 64 Equations used for force analysis of lifting mechanism 78 Appendix D POWeEFSUDSBOLIOL bon e L ____________ 82 Pump SpectHicatiOtis csse duipretiu SR E MINE IDEE 84 Appendix Safety DS AD 85 Appendix Platform SuUDSeCtIOE vocato t idet Neun EE
3. DREAWMN TITLE m 4 Side Bottom Bracket for Screw Adjustment APPROVED e _ TM Tl e O r es ME 1 Saluki Engineering PRODU 1 IvNOLLVOnQ3 3s301nv Ad PRODUCED BY AUTODESK EDUCATIONAL PRODUCT PRODUCED AN AUTODI 3 2 00 2 75 1 50 ESK EDUCATIONAL PRODUCT 2 CHECKED APPROVED DRAWN Matt Lane Saluki Engineering 4 22 2011 Front Top Bracket for Screw Adjustment 14 1 dk TVNOLLVS003 XS3001nv NV Ag PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED AN AUTODESK EDUCATIONAL PRODUCT 3 2 96 Matt Lane 4 22 2011 TITLE SHEET 1 OF 1 1 dk 19 IvNOLLVOnQO3 NY Ad PRODUCED BY AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AUTODE 3 1 2 13 2 97 EDUCATIONAL PRODUCT 2 DRAWN Thread Rod Adjustment APPROVED e oo ____________ 1 1 59001 Ga0ndOdd PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED AUTODE 3 AUTODESK 98 EDUCATIONAL PRODUCT 2 Ls Matt Lane Saluki E
4. SIZE DWG ND lt 1 10 ____ a Ty 2 1 TWNOLLWONGS 59901 Ag PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 5 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 2 4s DRAWN Matt Lane Saluki Engineering Bottom Stabalizer APPROWED or 1 1ondosd IvNOLLvOnd3 59001 Ag PRODUCED BY AUTODESK EDUCATIONAL PRODUCT 1 00 PRODUCED AUTODESK EDUCATIONAL PRODUCT 3 2 DRAWN Lane CHECKED FG APPROVED 3 PRODUCED AN AUTODESK EDUCATIONAL PRODUC 4 19 2011 as Saluki Engineering TITLE Top Stabalizer SIZE Da NO VEN 1 IvNOLLVOnG3 59 401 PRODUCED AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 IF 2 DRAWN Matt Lane 4 19 2011 CHECKED EIC D BY AN AUTODESK EDUCATIONA Saluki Engineering sdo das OF 1 WNOLLWONGS 59401 Ag Equations used force analysis of lifting mechanism Since the lifting mechanism subsystem is composed of two identical halves the force analysis was done only on one half of the mechanism to simplify the equations The right half
5. pki Be Design Report for Belly Pan Jack Prepared for Gibbs Construction Prepared by Saluki Engineering Company Team 56 F10 56 BELLYPAN Technical Advisor Dr Gary Butson Team Members Alex Gibbs ME PM Ross Heern ME Jason Webber ME Matt Lane ME Bradley M Wilson ME Blake Thurston ME April 26 2011 April 26 2011 Southern Illinois University Carbondale College of Engineering Mail Code 6603 Carbondale Illinois 62901 6604 Saluki Engineering Company dishmail net Greg Gibbs Gibbs Construction Co owner and Operator P O Box 11 Modesto Illinois 62667 618 527 8671 Dear Mr Gibbs Team 56 of the Saluki Engineering Company would like to thank you for the opportunity to design and build the belly pan jack The following design report contains all the information for the design and the prototype of the belly pan jack The main objective of this project 1 to design a safe and efficient tool to be used to remove and install belly pans In order to achieve this a number of different subsystems have been incorporated into the design The design incorporates the use of a top that will contact the belly pan and has the ability to tilt in two directions in order to adapt to the numerous shapes of belly pans The design also has an air over hydraulic pump for ease of use since an air supply will readily available in the client s shop The belly pan jack is easily moved thanks to the
6. 87 To M ADIT 21 c 99 CHASSIS TIE 101 crus caren 102 eu 102 ChassisuAsSs embly Em 103 C aster VV ICSI 103 Parts 104 Me ec 104 illia MEC Eo o e 105 Meehbamsm 105 wi 106 Slider Guide 106 Slider Guide Mechanism List o ee E 106 Slider Guide Mechanism Assembly Draw Ings 107 Top Slider Guide u E LI IL COD I 107 Patris TAC 107 Bottom S ider Se 107 Bottom Slider Guide Eutr pev 108 Power 108 Power System Parts EEE a eS se 109 P owersystemic ud MM M CM C D EUN 109 Power deena 109 Pump EMI NEM ME 109 109 lilo ei tan St M oed saam MD EO 110 Platform System Lisu u do caet dades 110 Platform os toto quide as uut
7. 110 APP UN IE 111 Service R kumu eme E uat E 111 CHISSI CC 111 ilor SO ne ee Er 112 112 PUMP 113 cuin esos SR CIIM IS D Le DO DEM kanta 114 USER ONP S NU achete O O 116 List Figures last aii MIELE LIU 11 Figure 2 BPJ 2000 i t Siaka 14 Figure 3 2000 Lifting Mechanism Subsystem 18 Figure 4 Cylinder Force Ram Length Table Height vs Scissor 23 BPI2000 Velocity EUSE Hp ddr dis 24 Figure o BPI 2000 Safety Plow Regulator a eh eei tha da id deett di ias t aen a 25 Figure 75 BPI 2000 Platform SUBS SOT iet e ee nale 28 Total Displacement with 2000 Ib eoa aun uan eon a one eiu quant 32 L ource 2000 1b 1030 uiaiia 33 Figure 10 Total Deformation with 300 Ib Lateral Load a nsn 34 35 Foure I2 Chassis Factor Ob 36 List Tables Table T BPI 2000 CHASSIS Parts ESU 17 Table 2
8. o aa 1onaosd WNOLLVONGS MSAGOLNY A8 Salukli Engineering 4 22 2011 DRAWN Matt Lane CHECKED _____ Assembly EN MEE MFG 2 x 1 E 16 2 _______ Front Bsck Bottom a F Top Bracket for Screw Adjustment a 2 rs Thread Rod For Top Adjustment c 87 a PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AUTODESK EDUCATIONAL PRODUCT 3 2 dk Matt Lane Lane 4 20 2011 Saluki Engineering mem t l T6 SHEET 1 OF 1 AN AUTODESK EDUCA 88 1390004 IvNOLLVOnQO3 MSSGOLNY Ad PRODUCED AN AUTODESK EDUCATIONAL PRODUCT PRODUCED AN AUTODESK EDUCATIONAL PRODUCT 3 2 DUCA Matt Lane Matt Lane 4 22 2011 Saluki Engineering p Ty SEE DWG REV a T 8 see or i 2 1 t k A Bi 1001004 59901 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT y 91 00 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT i 51 2 1 4 20 UNC 28 SECTION SCALE 5 1 PRODUCED BY AN AUTODESK ONAL 90 WNOLLWONGS 59401 NV Ad 2 3 PRODUCED BY AN
9. 1 IvNOLLvOnd3 MS3001nwv NY PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 2 51 5 25 4 DRAWN CHECKED Wa Caster Top Plate mos __ __ ok OS 2 SHEET 1 or 1 1 D BY AN AUTODESK TIONAL 48 Ls 1 WNOLLWONGS M3S3001nv PRODUCED BY AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 Y 2 49 DBAWN Caster Wheel m9 0 SIZE DWG HO rf fe 2 1 AME SHEET 1 OF 1 PRODU 1 WNOLLWONGSA M4S3001nv Ad PRODUCED BY AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 VD 2 3 375 EE Saluki Engineering Chassis Cylinder Bracket Bottom 5 APPROVED mom rm ori 1010049 59401 Ag qa3ondoHd PRODUCED AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AUTODESK EDUCATIONAL PRODUCT 3 2 DBAWN m mom 5 DWG _ apk 4 O sneer iooi IvNOLLVOnQ3 59401 Ag PRODUCED BY AUTODESK EDUCATIONA
10. 1ondosd S3 001nv Ad PRODUCED AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 2 SECTION SCALE 4 1 2 25 WNOLLVONGS HSS00LNV Ag PRODUCED AUTODESK EDUCATIONAL PRODUCT PRODUCED AN AUTODESK EDUCATIONAL PRODUCT 3 2 SCALE 25 1 rss x 2 2 j E i 4 a ___ 4 jis a ke 3 PRODUCED BY AN AUTODESK EDUCATIONA 72 DRAWN Matt Lane 4 19 2011 Saluki Engineering E 477 Lifting Mechanism APPROVED 1 OF 2 PRODL NV Ad PRODUCED BY AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 2 1 omen Matt Lane 4 15 2011 Saluki Engineering Cylinder Cross Member APPROVED ____ __ ooo OF 1 AUTODESK EDUCATIONAL 73 WNOLLVONGS sadolnv PRODUCED AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 5 2 4 T 1 D c R1 00 p 4175 ano 3 00 1 00 N R1 00 8 53 DRAWN Matt Lane 4 19 2011 Saluki Engineering ___ ___
11. Contents lE ogg ee 8 ra manu Qam ua 8 2 0 JECT Descr DMO Me 9 u ua i Sana uwa apa basi 9 2 2 Subsvstem Interac 10 2 3 Desi sii O EGRESS 12 97 1 SR GS OA 13 CHATS 14 9 2 DOSCHDLUOIT u ua 14 222752 DO SEGTIUPIEOGESS ED SEO AOR SASS MA cubi 15 3 2 SIS mL 15 ILAP LE was A 16 18 SI Technical Desc 18 3 2 2 ESTO so ep ue af 19 EY ALY EE 20 tune Da _ 21 j POW EL SUDSEC HON una a ama 21 9S4 u w ht amaata 21 S SOUP EO 22 3 4 5 22 24 S 24 3 5 2 De 26 S18 27
12. steel plates welded along the interior of 40 inch members which provide surface for the lifting system mounts to be welded to as well as a surface for the sliders to slide on The areas of highest stress where located using FEA Then gussets where added until the stress 1n the chassis was within satisfactory levels 3 2 2 Design Process The chassis subsystem Figure 2 is the foundation support of the belly pan jack It not only supports the lifting system but it also contains the power system and facilitates mobility by allowing the belly pan jack to roll freely via the large steel caster wheels The chassis design allows for a low profile and contributes to the belly pan jacks overall low clearance capabilities The chassis also houses the hydraulic pump and reservoir as well as the lower mount point for the lifting cylinder Along with contributing to the ease of mobility and connecting the power system to the lifting system the chassis supports the load of the lifting system 3 2 3 Fault Analysis Like the lifting system the most likely cause of failure to the chassis of the belly pan jack is due to over loading If the belly pan jack was loaded beyond its capacity it 1s possible that the chassis could fail in three modes The first would be bending in the frame which is the least catastrophic of the three possible failures If the frame where to fail the chassis would simply contact the ground which would then interfere with the
13. was taken out of the center of the pin However through proper maintenance and by not exceeding the recommended lifting capacity the jack will operate smoothly 3 3 4 Part List Table 2 Parts list of BPJ 2000 Lifting Mechanism 712 seis meen L4 SlierBase 4 LS SliderTab 8 L6 LongPin 8 Cylinder Support for Members io Short Pin NEN L9 Cylinder Cross Member 1 L 1 Bottom Slider Stabilizer 2 L 2 Top Slider Stabilizer 2 L3 Stabilizer Spacer 4 3 4 Power Subsection 3 4 1 Technical description The power system on the belly pan jack consists of a hydraulic cylinder hydraulic motor and an air over hydraulic pump One double acting hydraulic cylinder will be used however the cylinder will be plugged on one end so it acts as a single acting cylinder The maximum hydraulic pressure input is 3500 psi The maximum load rating for cylinder is 20 000 Ibs The hydraulic cylinder will extend from the bottom of the chassis to the mounting point on the scissor arms The cylinder must also be able to support the maximum load on the Jack while maintaining a factor of safety of 2 5 21 air over hydraulic pump will power the hydraulic cylinder compressed air supply is used to cycle a piston As the piston is compressed by air it will pump hydraulic fluid into the system Once fully compressed a one way hydraulic valve will clos
14. 1 4 AISI 1040 Steel Plate for Sliders On Hand 2 x 3 x1 4 wall thickness AISI 1040 Rectanguar Steel Tubing for Cylinder Mounting 10 50 3 8 Thick ASTM 1040 Steel Plate for Cylinder Mounting On Hand 1 4 AISI 1040 Steel Plate Reinforcements On Hand 1 4 151 1040 Steel Plate for Slider Braces On Hand 1 2 Spacer for Slider Braces 1 3 8 x 2 Bolts and nuts On Hand Chassis 1 x 2 x3 16 wall thickness 8500 Rectuangular Tubing for Frame 26 65 1 4 151 1040 Steel Plate for Lifting Mechanism Mounts On Hand 1 2 Thick AISI 1040 Steel Plate for Wheel Mounts On Hand 1 4 AISI 1040 Steel Plate for wheel Mounts On Hand 6 diameter 1500 Ib Caster Wheels 212 00 3 8 x 2 Bolts Nuts and Washers 25 00 1 4 151 1040 Plate Steel for Chassis Bracing On Hand 1 4 Thick AISI 1040 Steel Plate for Sliders On Hand 2 Steel Pipe for Handle On Hand 1 x 2 x 3 16 wall thickness 8500 Rectuangular Tubing for Handle 3 50 Platform 1 x 2 x 3 16 wall thicknass 8500 Rectuangular Tubing for Frame 26 65 1 4 Thick AISI 1040 Steel Plate for Sliders On Hand AISI 1040 Steel Plate for Platform Mounts On Hand thick Steel Bar Grate On Hand 1 5 x 1 5 Angle Iron for Grate On Hand 3 x 3 Angle Iron for Grate On Hand 1 8500 Stock for Pins 2 00 1 5 AISI 1040 Pin Stock for Bushings On Hand 1 4 Steel Plate Mounts for Screw Adjustments On Hand Screw assemblies 40 00 3 4 Washers for Screw Adjustments On Hand 2 Cotter Pin
15. 5356 0 5 0 191953 0 0 2 8 0 Fs 846 2 0 0338 0 5 0 0852 0030845 5 18 0 0 1 12 0 131396 2 5356 0 5 1131353 0 1 2 8 1 0 0 1692 0 03 38 0 5 0 0852 0033848 1 0 0 10420 2084 0 3675 0 141083 0 14108 14737 Since the force analysis was done on just half of the lifting mechanism the actual force in the cylinder have to be found by multiplying F by 2 81 Appendix Power Subsection PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 77 2 82 1210044 TvNOU vonaa MSSGOLNV NV PRODUCED AN AUTODESK EDUCATIONAL PRODUCT 2 3 PRODUCED AN AUTODESK EDUCATIONAL PRODUCT s am 1 YS3001NY A8 83 Pump Specifications Typical Set up Hook up for single acting cylinders PUMP AIR For use with Cyl Type Description Single Acting Base model pump with high density 50 polyethlene reservoir Single Acting except has metal reservoir PA50M Single Acting except has 12 foot remote control PASOR Single Acting 50 except has metal reservoir Single Acting except has 2 gallon reservoir PA50R2 Single and 50 except designed to operate either PA50D Double Acting single or double acting systems Valve fu
16. AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT a EF DP PF r 2 HELL d Lu au ura una u aD uS Jla 39 375 LONdOdd TWNOILWONGS Ag da3ondosd 3 a el DWG ND 1 10 PRODU AUTODES L EDILI A k 91 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 IF 2 AN AUTOD n Lane 4 22 2011 Saluki Engineering ae Top Screw Mount E 2717 is l 1 071 92 1390004 IvNOLLVOnQO3 HSSGOLNY PRODUCED BY AUTODESK EDUCATIONAL PRODUCT 50 PRODUCED AUTOD 3 1F fh 1 25 1 50 ESK EDUCATIONAL PRODUCT 2 CHECKED DRAWN Matt Lane 4 22 2011 2 TITLE Side Top Bracket for Screw Adjustment SIZE DWG NO EE ______ 1 1 WNOLLYONGSA 4S3001nv PRODUCED BY AUTODESK EDUCATIONAL PRODUCT 50 2 75 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 2 AU TOD dk 94 k
17. a positive safety device with the source of failure 15 in the fluid itself Taking these faults Into account the safety subsystem 15 a sound system and an adequate source of safety for the equipment operator and bystanders 3 5 4 Parts List Table 3 BPJ 2000 Safety Parts List 671 Part Description Quantity 27 3 6 Platform Subsystem Figure 7 BP J 2000 Platform Subsystem 3 6 1 Technical Description The lifting mechanism 15 linked to the base of the platform with a threaded rod The base of the platform 1s also linked to the top of the platform with a threaded rod The threaded rods can be rotated to adjust the tilt in both dimensions Both platforms are designed to tilt 8 degrees The ability to tilt makes it possible to orient the platform at any angle This makes positioning and aligning the lifted object into difficult mounting positions much easier and safer The lifting mechanism surface is made of a grating material This will allow for easy attachment of any fixture These would include both general manufactured fixtures and or 28 custom made to fit fixtures An example of the later would be a simple wood block cut to shape and then bolted to the surface The grated top mounting system allows for much more mounting flexibility than a standard flat top Finally the pins and threaded links were designed for easy removal This was done to allow for a multitude of different mounting systems For example a low profil
18. jack to prevent the belly pan Jack from dropping rapidly while loaded the control for the pump 1 a remote with a twelve foot long hose to keep the operator clear of the belly pan Jack The velocity fuse Figure 5 1 an line 90 elbow swivel with an NPTF outlet port that provides full line shut off In the event of line failure resulting In sudden loss of pressure The velocity fuse acts like an electrical fuse in that it 1s set at a predetermined flow rate for which the fuse will trip if that flow rate 1 met or exceeded After the fuse 1s tripped it holds the hydraulic 24 fluid the hydraulic cylinder until the fuse can be reset by applying pressure to the fuse to decrease the pressure differential to 50 psi simulating the ruptured hydraulic line being replaced and operated to raise the belly pan jack decreasing the pressure differential eventually reaching equilibrium and resetting the velocity fuse Exact dimensions and drawings can be found in Appendix E The flow regulator Figure 6 is an line hydraulic flow regulator with an NPTF outlet that regulates the flow of fluid into the pump and it occurs when the Jack is being lowered In this way the flow regulator provides the operator with added control preventing the belly pan Jack from being lowered too quickly while loaded Exact dimensions and drawings can be found in Appendix E The remote control for the pump is fully integrated into the pump itself The remote
19. of the mechanism was considered when completing the force analysis The following equations were obtained when while doing the force analysis b 30 5 0 a 1 302 x 30 x cos 20 2 sin 227 3 Fiy a Foy b 4 W Fiy Foy 5 15 cos 0 15 sin 0 Foy 30 cos 0 0 6 Fay Fey Foy 0 7 Fay 0 8 15 0 Fs 15 sin 15 cos 0 9 Fey Fay 0 10 Fey Fey 0 11 30 cos 15 cos 0 15 sin x 5 20 90 0 12 Fe sin 0 0 13 cos 0 0 14 15 78 The following table describes the variables used in above equations left end of the Lifting Surface end of Lifting Surface Distance between cylinder mounts and joint Length of the cylinder The next two figures show the schematics of the lifting surface and the lifting mechanism that was used for the force analysis The first figure 1s a figure of the lifting surface The point 1 represents the pin where the lifting mechanism 1 mounted to the lifting surface and point 2 represents the pin of the mechanism that is connected to the slider The second of the two figures shows one half of the lifting mechanism and the numbered joints tha
20. the remote control to raise the jack until it just touches the object excessive force 1s not necessary while keeping clear of the scissor mechanism Lowering the Jack ALWAYS STAY CLEAR OF THE SCISSOR MECHANISM When ready to lower jack ensure that all hoses tools or any other objects are clear of the scissor mechanism When the scissor mechanism 1 clear of objects press the lower button on the remote control and FULLY LOWER JACK BEFORE MANEUVERING FAILURE TO FOLLOW THIS USER S MANUAL CAN CAUSE PERSONAL INJURY OR DEATH 119 Appendix Service Charts Chassis Service 1 8 JGreaseFitting 8Hours Grease Fitting Hours 3 8 sreaseFitting 8Hours Hours 120 Platform Service Caster Wheel Service Service Location Discription Interval 8 GreaseFitting 8 Hours rease Fitting S 8 rease Fitting Hours rease Fitting 8 Hours 121
21. the subsystems of the belly pan jack Lifting Surface Lifting Mechanism Figure 1 Block Diagram 11 2 3 Design Considerations The chassis subsystem was the simplest to design of all the subsystems because the function of the chassis 1s simple provides support to the lifting mechanism has the stability to the Jack as a whole and can be easily maneuvered The support and stability was easily achieved by designing the chassis to have a good sturdy frame and having large heavy duty caster wheels These large heavy duty 6 inch steel caster wheels along with a handle provide the jack with the ability to be easily maneuvered when fully loaded with a belly pan Several considerations went into designing the power subsystem Different actuators such as air bags screw actuators and hydraulic cylinders were considered in the design process The hydraulic cylinder was eventually decided upon because of the ease of operating the cylinder The cylinder could be operated with a hydraulic pump where as an air bag uses air as the working fluid which is not as simple to work with as hydraulic fluid a screw actuator would have needed a means of turning the screw to move the lifting mechanism Once the actuator had been selected the air over hydraulic pump was selected to supply the hydraulic fluid to the cylinder This pneumatically controlled pump was selected because the air supply 1s readily available places where the Jack
22. 1 twelve feet long and allows the jack to be controlled from a distance of twelve feet and keeps the operator clear of the jack while lifting and lowering In this way it greatly decreases the chance of injury to the operator 2 CONTROLLED FLOW AS MARKED Figure 6 BPJ 2000 Safety Flow Regulator 2 25 3 5 2 Design Process Originally the safety mechanism was a mechanical mechanism integrated into the lifting mechanism which would lock the jack in place as it rose This however was altered to a hydraulic safety valve known as a velocity fuse The velocity fuse reduces the weight of the belly pan Jack as well as lowering the cost and maintenance required for the belly pan jack The velocity fuse allows uncontrolled flow in one direction into the cylinder and allows monitored flow the other direction out of the cylinder In order to monitor the flow the fuse was set at a predetermined flow rate for which the fuse would close off flow out of the cylinder The velocity fuse was used in conjunction with a flow regulator The flow regulator allows uncontrolled flow one direction out of the pump while controlling the flow in the other direction into the pump which facilitates the jack being lowered The flow regulator was also set at a predetermined flow which was achieved by the specs of the pump Since the pump pumps a minimum of 28 cubic inches per minute at maximum pressure and a maximum of 108 cubic inches per minute at minimu
23. 2 Parts listof BPI 2000 uuu 21 Table 000 Satety Parts EIS ak SS 27 Table 4 2000 Platform Parts i deret bo 30 Table Cost to TI plement 2900 tiii 38 Table 6 BPJ 2000P Implementation Schedule sissen a 40 1 0 Executive Summary The Saluki Engineering Company SEC design team 56 constructed the prototype of a belly pan jack for Gibbs Construction The purpose of this jack 1s to provide an efficient means of removing and installing belly pans on heavy equipment such as bulldozers The final design 1s a direct representation of the design presented in the design proposal with only minor changes This report 1 divided into sections that were given to the team members to write To begin the report 15 a general section which contains an introduction to the project and why it 15 needed an overview of the project a cost break down of the design and a timeline for implementation After the general section the subsystem section of the report 1s presented and it contains the five major subsystems of the design This 1s followed by a User s Guide Technical Manual and the final parts of the report are the Appendices In comparison to other lifting devices such as tables or transmission Jacks designed belly pan jack 1 superior due to its performance speci
24. ALL DIMENSIONS IN INCHES CAVIIYTHREAD RATEDFLOw t r 5 so FUSE NOSE REQUIRES A DEEPER TAP DRILL DEPTH SEE DIM P Range of applicable set flow rate the setting used was 0 35 GPM 85 L DESCRIPTION AN IN LINE PRESSURE COMPENSATED NONADJUSTABLE FLOW REGULATOR WITH FEMALE NPT PORTS INTENDED FOR FIXED DISPLACEMENT HYDRAULIC CIRCUIT APPLICATIONS OPERATION IN THE CONTROLLED DIRECTION THIS REGULATOR WILL MAINTAIN A CONSTANT FLOW RATE THROUGHOUT A SPECIFIED PRESSURE RANGE REVERSE FLOW PASSES THROUGH THE CONTROLLING ORIFICE AND IS UNCONTROLLED PRODUCING A PRESSURE DIFFERENTIAL OF 120 PSI MAX AT 150 OF CONTROLLED FLOW HEX FEATURES SURGES INTERNALLY DAMPENED FEATURE IS OPTIONAL FOR LOAD LOWERING APPLICATIONS AS MARKED STEEL BODY STEEL INTERNALS HYDRAULIC FLUIDS GENERAL TYFICAL PERFORMANCE SPECIFICATIONS ORDERING INFORMATION ASSEMBLY NUMBER iX DAMPENED 1 0 1 Temperature Range 250 F to 40 F REGULATED FLOW RATE Flow Tolerance 10 ALL DIMENSIONS IN INCHES MODEL PORT 12 FLOW RANGE 1352 1 4 18 NPT 0 25 4 0 GPM 0 938 Range of applicable set flow rate the setting used was 0 25 GPM Hydraulic Symbol 86 lon Platform Subsect Appendix F PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 2 3 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT M N 5
25. DWG L1 5 aum PRO 1 D 43 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT e ar Saluki Engineering DWG NO 4 19 2011 seer or d Chassis Side Chassis APPROVED Wi PRODUCE 3 d 2 44 PRODUCED BY AUTODESK EDUCATIONAL PRODUCT PRODUCED AUTODESK EDUCATIONAL PRODUCT 3 2 wu 2 AU TOD 45 Matt Lane 4 19 2011 Saluki Engineering Chassis Plate me 5 DWG LL semi Or 1 as LONGOYd WNOLLVONGS XS3Q01nv Ag PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED AN AUTODI 3 46 ESK EDUCATIONAL PRODUCT 2 dk 4 DRAWN TEE om mom SIZE DWG HO fe ls 2 SHEET 1 Ori 1 PRODU 1 Xs3dolnv PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AUTOD 3 4 EDUCATIONAL PRODUCT 2 dk Chassis Caster Mount gt gt cl ke 2 DRAWN Matt Lane 4 19 2011 EE 1
26. E 15 0 TAP DRILL P MIN FEATURES SWIVEL DESIGN FOR EASY ALIGNMENT CLOSING FLOW _ 90 ELBOW FOR LOW PROFILE APPLICATIONS FAIL SAFE EMBEDDED FUSE DESIGN STEEL BODY amp COMPONENTS RAPID RESPONSE REVERSE FREE POSITIVE CLOSE FLOW CLOSING FLOW SPECIFICATIONS Hydraulic Symbol ORDERING INFORMATION ASSEMBLY NUMBER T Operating Pressure 3500 PSI SERIES NUMBER OUTLET PORT SIZE Temperature Range 250 F to 40 F CLOSING FLOW GPM Reopening Differential 50 PSI ALL DIMENSIONS IN INCHES THREAD __ P L N FUSE NOSE REQUIRES A DEEPER DRILL DEPTH SEE DIM 114 DESCRIPTION AN IN LINE PRESSURE COMPENSATED NONADJUSTABLE FLOW REGULATOR WITH FEMALE PORTS INTENDED FOR FIXED DISPLACEMENT HYDRAULIC CIRCUIT APPLICATIONS OPERATION IN THE CONTROLLED DIRECTION THIS REGULATOR WILL MAINTAIN A CONSTANT FLOW RATE THROUGHOUT A SPECIFIED PRESSURE RANGE REVERSE FLOW PASSES THROUGH THE CONTROLLING ORIFICE AND IS UNCONTROLLED PRODUCING A PRESSURE DIFFERENTIAL OF 120 PSI AT 150 OF CONTROLLED FLOW CONTROLLED FLOW 5 EXE 505085 INTERNALLY DAMPENED FEATURE IS OPTIONAL FOR LOAD LOWERING APPLICATIONS STEEL BODY STEEL INTERNALS TYPICAL PERFORMANCE HYDRAULIC FLUIDS GENERAL SPECIFICATIONS Hydraulic Symbol ORDERING INFORMA
27. L PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 2 1 00 Saluki Engineering MEME 2 ntes APPROVED E C 11 ____________ 1 52 1 WNOLLYONGS NV PRODUCED AUTODESK EDUCATIONAL PRODUCT PRODUCED AN AUTODESK EDUCATIONAL PRODUCT 3 2 2 00 TWNOLLVONOS 4S3001nv Ag PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 WF z 1 422 Jos CHECKED Pump box bottom plate cu lsi _________ oF 1 Matt Lane 4 23 2011 TITLE z AN AUTODESK EDUCA PRODUC 54 1390004 IvNOLLVOnQO3 HS30OLNY PRODUCED AUTODESK EDUCATIONAL PRODUCT x 12 00 PRODUCED BY AUTODESK EDUCATIONAL PRODUCT 3 a _ D BY AN AUTODESK EDUCATIONAL PRODUC 55 mm 1on osd IwMNOLLvoncd3 Xsaqdolnv Ag PRODUCED AN AUTODESK EDUCATIONAL PRODUCT 56 PRODUCED BY AUTODESK EDUCATIONAL PRODUCT LS CHECKED Em 1 Chassis Bottom Support APPROVED 6 _ or 1 1 Mariae Matt Lane 4 19 2011 Saluki Engineering 1on
28. TION ASSEMBLY NUMBER DAMPENED S L0 1 Temperature Range 250 F to 40 F REGULATED FLOW RATE GPM ALL DIMENSIONS IN INCHES 115 2000 USERS MANUAL Preface Thank you for purchasing your BPJ 2000 belly pan Jack The Saluki Engineering Company would like to thank you for your purchase Our dedication to quality and performance will ensure your complete satisfaction with our product Before using your BPJ 2000 please read and understand this user s manual Use of this product without a complete understanding of this manual could cause personal injury or death Once again thank you for your purchase if you require any additional information feel free to contact us Sincerely Management of Team 56 Saluki Engineering Company Southern Illinois University Carbondale College of Engineering Mail Code 6603 Carbondale Illinois 62901 6604 117 Please read and understand the following warnings before continuing e Before use of jack thoroughly read and understand the user s manual e Only use jack on level surfaces e Never exceed the rated load capacity of the jack of 2000 LBS Always keep the load centered on jack e Never supply more than 120 PSI of air pressure to the hydraulic pump e Keep hands arms and tools away from scissor mechanism while in motion Always secure remote leads to handle when maneuvering the jack Never maneuver Jack without completely lowering the load e Alw
29. Ty 2 PROD 66 1 TWNOLLWONOS HSSCOLNY NV EDUCATIONAL PRODUCT D BY AN AUTODE PRODUCE PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT e t 5 Td Ty WNOLLWONGS 300 Ad daondosd Lane Saluki Engineering 4 19 2011 CHECKED APPROVED SHEET 1 OF 1 DWG NO L 3 2 PRODUC 67 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED AN AUTODESK EDUCATIONAL PRODUCT 3 2 2 00 F R125 b DRAWN Matt Lane 4 19 2011 CHECKED Saluki Engineering C L 4 SHEET 1 OF 1 1 WNOLLVONGS Xs3dolnwv Ag PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 2 h AN ALITODI dk pi 69 y CHECKED MERE 2 DRAWN 4 19 2011 Slider Tab SIZE DWG El ds SOME uer 1 pri 1 WNOLLVONGS 8539901 Ad PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 5 D BY dk pi PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 3 2 CHECKED DRAWN Matt Lane 4 19 2011 MFG Te 2 70 4 c ________ 1 7 AE 1
30. ace 15 beneath the track keeping the sliders from coming off of the track in case the belly pan jack was loaded improperly The final parts of the lifting mechanism that were assembled are the mounting brackets for the cylinder The cross member of the lifting mechanism which carries all the force from the cylinder is made of AISI 1040 rectangular steel tubing Welded to this cross member are mounting brackets for the cylinder 3 3 2 Design Process The lifting mechanism Figure 3 is the core of the belly pan jack as it provides the lifting support and determines the motion of travel for the lifting surface The lifting mechanism is connected to the 19 chassis subsystem and the lifting surface subsystem with the power subsystem integrated into it to provide power for lifting considerable amount of time and effort went into designing the lifting mechanism During the design process several design parameters were considered these design parameters are the lifting surface must travel only in the vertical direction the mechanism must collapse fold down to a height of 18 inches to be able to accommodate machines with low ground clearances as well as reach a height of 55 inches when fully extended to accommodate tall machines as well Several different designs were considered and the scissors type of lifting mechanism shown in Figure 3 was chosen because it best suited the design parameters Once the type of lifting mechanism had bee
31. arge portion of the materials used in building the prototype Chuck was able to sell the materials to Team 56 at his cost which greatly reduced the total cost of the prototype Chuck also helped in the design of the belly pan jack by making suggestions as to what materials should be used The final thanks has to be given to Greg Gibbs owner of Gibbs Construction for giving us the opportunity to design the belly pan jack When preparing this report each team member was assigned specific sections to complete Alex Gibbs was given the power subsystem the end of project memo and the job of reading the final report to ensure that each section fit together nicely as well as writing the user s and technical manual and appendices Ross Heern was assigned the safety subsystem and the Appendix E which contains the equations used to determine the size of the velocity fuse Jason Webber was assigned the lifting surface subsystem Bradley M Wilson was assigned the chassis subsystem and the job of putting all parts of the reports together and making the table of contents Matt Lane was given the job of making all the Autodesk Inventor drawings and the detailed part drawings throughout the report and in the appendices of the report Blake Thurston was given the general section of the report the lifting mechanism subsystem and Appendix C which contains the equations and spread sheet used in completing the force analysis of the lifting mechanism Table
32. ays clear planned path of travel of any obstructing objects e Failure to heed these warnings can cause person injury or death Intended Use This jack was designed and intended with a sole purpose of raising lowering and transport of belly pans of large earthmoving equipment on level shop floors Any other use is NOT recommended by the manufacture and Saluki Engineering Company will NOT be liable for misuse of this product 118 ALWAYS HAVE LOAD FULLY LOWERED BEFORE MANEUVERING JACK Make certain that the remote control leads are secured on the handle before moving Check path of travel for rocks cables hoses or any object which might hinder the travel of the jack Lock wheels via the swivel locks if desired Using the handle maneuver the jack into the desired position Tilting Top ONLY ADJUST TOP WITH JACK AT REST IF LOADED MAKE SURE THE LOAD IS SECURE BEFORE ADJUSTING If adjusting the angle of the top of the jack 15 necessary adjust with supplied tools to match the desired angle Raising the Jack ALWAYS STAY CLEAR OF THE SCISSOR MECHANISM ONLY OPERATE JACK ON LEVEL SURFACE After maneuvering jack into the desired position check the surface of the object intended to be made contact with Check that the surface 15 clear of any buildup of mud sticks or any other foreign material that may jeopardize the securing of the object Once object has been prepared for contact press the raise button on
33. belly pan Jack The subsystems are the chassis the lifting mechanism power system safety system and the lifting surface Each subsystem is equally important in the operation of the belly pan jack This section will explain in detail how each subsection works and give a detailed description of the individual pieces of the subsystems 13 3 2 Chassis Figure 2 2000 Chassis 3 2 1 Technical Description To make the belly pan jack easy to move while loaded four 6 inch locking steel caster wheels where chosen for their low rolling resistance and long life These wheels are mounted snugly to the chassis and allow the chassis to sit very close to the ground which enhances the stability of the entire Jack Along with the wheels the chassis has pivoting handle to use while moving the belly pan jack The handle 1s four feet long which allows for the operator to pull the belly pan out from under the machine without crawling under it The handle also has a hitch at the end for towing the belly pan jack with a forklift or other small implement when it 15 fully loaded The handle also has two hooks to be used a storage device for the leads that go to the power system s remote control At the base of the handle is the power system containment box which securely houses the hydraulic pump The frame of the chassis 15 constructed from 1x2x 0 1875 inch rectangular tubing The steel tubing 1s welded into a rectangle of 27x40 inches with 14
34. debris Proper lubrication of the contacting surface of the feet 1s also important Use a standard No 2 grease to lubricate this area as needed Slider Guide Mechanism Slider Guide Mechanism Parts List Parts List Quantity Description Cylinder Cross Member L L Bottom Slider Guide L L12 Top Slider Guide pacer 1 bo 2 L0 Cylinder Bracket 1 bu 9 10 11 12 13 106 Slider Guide Mechanism Assembly Drawings Top Slider Guide T N 9 3W ott ALT Parts List Description 0 625 Grade 8 Flat Washer 0 5x1 5 Coarse Grade 8 Bolt 0 4 625 8 Bottom Slider Guide 107 Bottom Slider Guide Parts List c 2 5 Z Bottom Slider Guide 0 625 Grade 8 Flat Washer 0 5 1 5 Coarse Grade 8 Bolt 5HB 625 Coarse Grade 8 Nut 0 5N Power System 108 Power System Parts List Description 4 25 Pm with Manufactured Head Power System Cylinder The power system 15 designed for a 12x1 25 3500 PSI cylinder with a required retracted length of 22 inches Power System Pump The hydraulic pump that powers the cylinder is a Power Team model PASOR A detailed description of this pump is located in the appendix of this manual Pump Maintenance The hydraulic pump of
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36. e and a spring returns the piston back to initial stage to start the cycle over The pump is capable of producing a hydraulic pressure 3200 psi with and input air pressure of 120 psi Controls will be fully integrated for easy operation of the jack The control for the system 1s a remote air valve The valve has one button for raising the cylinder and one button for lowering the cylinder The cylinder will be raised by the hydraulic pressure produced by the pump Since the double acting cylinder 15 plugged the weight of the table will provide the force to lower the jack when the lowering button is pushed to open the valve 3 4 2 Design Process The hydraulic cylinder was chosen so that the maximum lifting capacity of the belly pan Jack could be safely supported The parameters that were considered when choosing the hydraulic cylinder were the bore rod diameter max load and maximum pushing force Since the cylinder is not required to pull it will be plugged at the top end so that it acts as a single acting cylinder An air over hydraulic pump was chosen so that the jack could be used in a variety of places without the need of electricity The parameters that were considered when choosing the pump were the maximum air pressure supported maximum oil pressure created reservoir size and ease of use 3 4 3 Fault Analysis The power system 1 most likely to fail when a maximum load is present and the scissor members are in a position produci
37. e these protective plates are often referred to as belly pans Belly pans are large bulky difficult and dangerous to remove and return beneath the machine Methods of removing belly pans have consisted of using a crane to apply force to a strap from one side of the machine anchored to the opposite side of the machine and put tension on the strap to support the belly pan Obviously a major problem with this 1s safety as well as effectiveness not to mention the availability of a crane Other methods involve using several different Jacks in conjunction with blocks to lift the belly pan Safety and effectiveness are concerns with this method as well There are a number of transmission jacks and lift tables that may work but safety and effectiveness are still a major concern because the manufacturer did not design the device for such conditions Among safety and effectiveness dependability ease of operation ease of maintenance maneuverability and cost were considered when designing the belly pan jack The designed belly pan Jack will provide a safe and effective way of removing and replacing the belly pan be easily maneuvered have fully integrated controls be easy to work around while in the open shop as well as under the machine and be cost effective The subsystems which the belly pan jack consists of are a safety mechanism main lifting mechanism power system chassis and platform lifting surface The belly pan jack will be easi
38. e flat top could be mounted to the system for low clearance situations Also custom tops can be manufactured for applications which the standard mounting system 15 inadequate 3 6 2 Design Process The platform subsystem 15 used to connect the lifting mechanism to the object to be supported The objects to be supported will have varying shapes and sizes This brings the need for a platform that 1s capable of fitting a wide variety of objects To accomplish this the base of the platform 1s connected to the lifting mechanism with two pins on each side The base of the platform 15 also attached to the top of the platform with pins The pin connections allow the platform to tilt in two dimensions The pin holes had a sleeve welded onto them to increase surface area contact to reduce wear The pins were also equipped with grease fittings to allow for greasing of the pins without removal 3 6 3 Fault Analysis The platform system 1 most likely to fail in a situation where a maximum load 1 present The maximum load the system 15 rated for 1s 2 000 pounds The factor of safety the system 15 designed with 1 2 5 meaning failure 1 possible with any loading above 5 000 pounds However the load rating 1s for a relatively centered load The specifications require that the center of eravity of the load not move more that 25 of the total length from the center of the platform on 29 the long axis of the table and the center of gravity should not move
39. ee to four weeks depending upon the machining skills and knowledge of the person completing the task The time for implementation could be reduced considerably if a manufacturing process was implemented or multiple people worked on the task together 39 Table 6 BPJ 2000P Implementation Schedule Time Cut material for pump mounting 000000000000 Cut material for pump mounting Cut and mill lifting mechanism 4 Assemble stabilizers to sliders 9 4 and machine pins for platform mounts Fabicaegraeforsuaee Fabricate grate for surface Power Subsystem Safety Subsystem 0000 6 40 m 10 15 5 1 1 7 0 Conclusion and Recommendations The belly pan jack offers a complete easy to use and effective way of safely removing and reattaching belly pans to large machinery The designed belly pan jack will greatly improve the safety and reduce the amount of time required by the current methods used for the removal of belly pans One large advantage of this design 15 the lifting surface By implementing a lifting surface that has the ability to tilt in two directions as well as the ability to attach fixtures to the lifting surface enables the belly pan jack to accommodate the various sizes and shapes of belly pans However if the device 1 going to be considered for manufacturing a couple changes to the design
40. fications and its ability to adapt to numerous applications Unlike most other lifting devices on the market the designed belly pan Jack has several safety devices to protect the operator The first safety device utilized 1s a remote controlled pump which allows the operator to be away from the jack when raising or lowering the belly pans Another safety device incorporated into the design 1 a velocity fuse on the pump which only allows a certain amount of oil flow before the fuse closes and no oil 15 allowed to flow which will ensure if the hydraulics fail the jack will not fall Another advantage of the designed belly pan jack is the lifting surface s ability to tilt to two directions allowing it to accommodate various sizes and shapes of belly pans In considering the project as a schedule we began designing the belly pan jack in September 2010 and completed the prototype in April 2011 The total cost for the prototype was 1 110 09 However many parts were made of materials on hand and the labor was free of charge 2 0 Project Description 2 1 General Description In the heavy machinery industry equipment needs to be serviced on a regular basis When purchasing equipment one looks at the value cost dependability ease of operation and ease of maintenance of the machine In many cases the maintenance of the machinery is among the most important Many areas of maintenance involve the removal of protective plates from beneath the machin
41. gure 9 Stress with 2000 Ib load The next figure Figure 10 shows the total displacement of the jack with a lateral force of 300 lbf This lateral force was applied horizontally to simulate the event of the jack being bumped by another object or by hitting an object when the jack is being pulled across the floor The results from this simulation show that the deformation only increases by a small amount from the deformation produced with only a load on the top 33 Figure 10 Total Deformation with 300 Ib Lateral Load Another area of concern is the bottom of the chassis that supports the cylinder Figure 11 shows the maximum force that the cylinder would exert and where the stress concentrations are As can be seen the design withstands the load Figure 12 shows the factor of safety rendering of the chassis With only the only low areas being where some pieces are welded the overall design is very good 34 Von Stress Unit ksi 4 25 2011 8 58 43 30 41 Max 24 32 18 24 12 16 Min Figure 11 Chassis FEA 35 Safety Factor Unit ul 4 25 2011 9 03 22 PM 15 Max Figure 12 Chassis Factor of Safety 36 5 0 Construction Cost An itemized cost list of the materials and parts needed to build the belly pan jack prototype AII of the steel needed for the different subsystems that the client did not already have was purchased from DMS Welding and Machine in Vergennes Illin
42. large six inch diameter steel caster wheels The belly pan jack also incorporates a velocity fuse and a hydraulic flow regulator as the safety mechanism Another important safety feature of the Jack 1s that it can be operated remotely allowing the mechanic to be out of the way The cost to build the prototype was 1 110 09 If you have any questions comments or concerns feel free to contact Alex Gibbs at 618 527 8673 or email gbg dishmail net Thank you again for allowing us to design the belly pan jack Sincerely Alex Gibbs Project Manager Team 56 Bellypan Jack Acknowledements There are several people that were of great help designing the belly pan Jack Dr Gary Butson was of great assistance when designing the lifting mechanism Dr Butson s knowledge of structures and force analysis helped determine the forces that were generated in each member which allowed us to determine the amount of force needed to be provided by the cylinder Since the prototype of the belly pan jack was not contracted out the machining was done in the MEEP machine shop and at Gibbs Construction s shop Tim Attig s knowledge of machining tools and his willingness to allow us to work in his shop 1 greatly appreciated Without the use of the MEEP machine shop and Tim s knowledge of setting up the machines the belly pan jack would not have been able to be built Team 56 would also like to thank Chuck Evans of DMS Welding and Machine for supplying a l
43. ly situated beneath the machine the wheels locked connected to the shop air supply raised to the belly pan the belly pan unbolted the Jack will then be lowered and the belly pan taken to be cleaned and service on the machine can be done easily The innovative user friendly design of the belly pan jack makes it an excellent choice for the service of large machinery 2 2 Subsystem Interaction There are five major subsystems of the design belly pan jack The subsystems are the chassis the lifting mechanism power safety and the lifting surface The chassis of the belly pan 10 Jack provides good stability when in operation as well as good mobility once the pan has been removed from the machine and needs to be relocated to be cleaned and for the machine to be serviced Attached to the top of the chassis are the lifting mechanism and power subsystems These two subsystems combine to provide the functionality of the jack The lifting mechanism provides the lifting surface with stability as well as a direction of travel while the power subsystem provides the lifting mechanism with the force needed to lift the belly pan Incorporated into the power subsystem 1s the safety subsystem which allows the operator to confidently use the belly pan jack Attached to the lifting mechanism 15 the lifting surface which allows the jack to be used for various sizes and shapes of belly pans A block diagram shown in Figure 1 shows the relationships between
44. m Caster mount inside Handle support Pump box side plate Pump box bottom plate Pump box back plate bottom support Handle Mount Side Yoke Top Yoke Handle Pipe Tow Ring Handle Bolt Handle nut Handle Grip 17 3 3 Lifting Mechanism Figure 3 BPJ 2000 Lifting Mechanism Subsystem 3 3 1 Technical Description The main parts of the lifting mechanism are the lifting members There are a total of eight lifting members which have an overall length of 33 inches each The lifting members were made of ASTM A500 steel which is a structural steel to withstand the forces generated at the joints of the mechanism The only difference in the eight members 1 that two of the members which the cylinder mounts to have extra steel plate welded to them to increase their strength to accommodate the large force that is applied there Three holes were drilled in each member to allow the members to be connected to each other as well as the other subsystems Bushings sleeves were then machined from cold rolled stock and welded into the holes To connect the members to each other and the other subsystems sixteen pins were machined from stress proof pin stock Eight of these pins were made to 3 125 inches long to connect the members to each other and the other eight pins were made to a length of 2 25 inches to connect the members to the sliders of other subsystems The pins were machined to incorporate a grease fitting 50 the joints of the lifti
45. m Cynder 109 Power LA t 109 Pump 109 utn 109 TR 110 vste ni Paris RERO Ne M 110 110 ppo ii UU mE 111 CBOE SD i ESO DE A 111 CHASSIS DEVIC Onenna C 111 c 112 Caster Wheel kan aA 112 Pomp e i 113 Valve Sa Tale 114 100 Chassis 101 Chassis Parts List Parts List tem Quantity Part Number 2 escription arrow Chassis ide Chassis 21210 aster Plate Caster Wheel Cylinder Bracket Bottom C 10 Caster Mount Inside C 11 Handle Support Pump Box Side Plate Pump Box Bottom Plate Pump Box Back Plate Bottom Support Handle Moun
46. m pressure the flow regulator was set to 58 cubic inches per minute a value which allows the belly pan Jack to be lowered at a controlled and efficient speed The velocity fuse was set at a trip flow which was suggested to be 40 higher than the maximum flow rate in the controlled direction This 1 to protect against surges on initial startup Since the regulated flow was set to 58 cubic inches per minute the velocity fuse was set to trip at 81 cubic inches per minute This elevated flow rate will only be reached in the event of a ruptured line or fitting 26 3 5 3 Fault Analysis It is worth stating that the likelihood of failure of the safety subsection 15 unlikely but several sources of failure are mentioned Possible failure of the safety subsection resides in the flow regulator and velocity fuse as well as the cylinder itself Although the likelihood of failure of the velocity fuse and regulator 15 minimal it 15 still worth noting that all devices have a limited life and can fail at any moment due to unforeseen circumstances That said the integrity of the flow regulator and velocity fuse are found to be sound and of top quality Also a source of failure 15 the hydraulic cylinder itself Since the velocity fuse 15 set to trip the event of a ruptured line the fuse uses the cylinder to stop the belly pan jack from dropping the cylinder could possibly break This 1s unlikely though and generally steel lines and cylinders are considered
47. may be considered The design of the lifting surface requires a tall profile Once the lifting surface was built and the belly pan jack was completely constructed the overall height was very close to 18 inches which 1 the needed clearance for low ground clearance machines A possible design that reduces the height of the lifting surface 1 to simply put a flat rigid top on the jack which allows blocks and other fixtures to be secured to would still allow the belly pan jack to accommodate the various sizes and shapes of belly pans Another design change that may be considered is to use a different material such an aluminum which would greatly reduce the overall weight of the jack Also a design that could allow the belly pan jack to be used other conditions such as on the job in the dirt and mud could be considered 41 Appendix General Appendices References 1 DMS Welding and Machine 696 Bethel Road Vergennes IL 629941408 2 http www vonberg com flow regulating valves 1350 htm Appendix B Chassis Subsection 42 EDUCATIONAL PRODUCT PRODUCED AN AUTODE 2 3 22 E x PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT u e inside box side plat box Pump box back plate cpu ort inder Bracket bottom ml PE he III REGEEHEE 1 IwNOLLVOnG3 Ad Ga9nd0dd Saluki Engineering
48. more 25 of the total width from the center on the shorter axis A load scheme outside of this range does not necessarily mean a failure will occur however any loads placed outside of this range may significantly increase the strain on parts to levels above the factor safety and also cause permanent damage to the system 3 6 4 Parts List Table 4 BPJ 2000 Platform Parts List PARTS LIST QY PART NUMBER DESCRIPTION COMMENTS 1 2 12 7 Narrow Chassis 5 2 2 2 4 4 5 mb seat Cs gg 2 6 24 J 7 7 8 78 8 24 19 2 9 1 49 10 11 Jj jToScewMont 1 2 142 Side Top Bracket for Screw Adjustment I 12 2 143 Side Bottom Bracket for Screw Adjustment 13 4 1441 Top Bracket for Screw Adjustment 4 4 J T15 Screw Adjuster 15 2 14 Thread Adjustment 16 2 747 9 JjTopHonfBakBotom 30 4 0 Performance Extensive testing was performed on the functionality of the belly pan jack in the application in which it was designed for The belly pan jack was physically used under a bulldozer to ensure the design would do what it was supposed to do The tilting top was also tested by setting different shaped belly pans on it which it adapted to with ease The remote control for the power system operates very well and allows the operator
49. n decided upon a complete force analysis was done on the lifting members The equations used and the matrix that was constructed can been seen in Appendix B A force analysis was done to determine the amount of force is generated at the joints of the members as well as to determine the lifting force required by the power subsystem to lift the load The lifting mechanism was design to safely lift a weight of 2000 Ibs This incorporates a factor of safety of 2 5 so the maximum load is quite adequate to accommodate the weight of most belly pans 3 3 3 Fault Analysis The most likely cause of failure in the lifting mechanism 1 by over loading the belly pan jack If the belly pan jack were over loaded the cylinder or cylinder mount would fail first The cylinder mounts are transmitting a considerable amount of force from the cylinder to the lifting mechanism The cylinder mounts are also made of mild strength steel where the lifting members are made of high strength steel However the cylinder mounts were design to fail first because the mounts would be a simpler or quicker fix than if one of the members failed by bending or fracturing The second most likely source of failure would occur in the shearing of a pin which connects the members together At the points of the lifting mechanism where the members are joined together the pins 20 are only in single shear Increasing probability of the pins to shear is the grease cavity where material
50. nction Advance Return 9504 3 way 4 Req d psi 40 120 40 120 40 120 40 120 40 120 40 120 Notes Air inlet port 1 4 NPTF Requires 20 cfm at 100 psi shop air pressure at the pump 84 Cap cu in 105 105 105 105 2 gal 105 Reservoir Usable cu in 98 98 98 98 454 98 Oil Port in NPTF Ya NPTF Ya NPTF Ya NPTF Ya NPTF Ys NPTF Prod Ibs 14 2 16 2 18 5 20 5 28 5 18 4 Appendix Safety Subsection L NPTF PORT DESCRIPTION AN IN LINE 90 ELBOW SWIVEL VELOCITY FUSE WITH AN NPTF OUTLET PORT THAT PROVIDES FULL LINE SHUT OFF IN THE EVENT OF A LINE FAILURE N OPERATION FLOW BELOW THE SPECIFIED CLOSING FLOW IS ALLOWED FROM 1 2 oF 50 FLOW ABOVE THE SPECIFIED CLOSING FLOW FROM 1 2 IS ASSUMED A LINE FAILURE AND IS BLOCKED Ni FLOW FROM 2 TO PASSES THRU THE CONTROLLING ORIFICE BUT IS UNCONTROLLED w Y CLOSING FLOW TOLERANCE 15 0 FEATURES vx SWIVEL DESIGN FOR EASY ALIGNMENT P MIN 90 ELBOW FOR LOW PROFILE APPLICATIONS FAIL SAFE EMBEDDED FUSE DESIGN CLOSING FLOW _ STEEL BODY amp COMPONENTS RAPID RESPONSE POSITIVE CLOSE REVERSE FREE FLOW CLOSING FLOW SPECIFICATIONS ASSEMBLY NUMBER Operating Pressure SERIES NUMBER OUTLET PORT SIZE Temperature Range CLOSING FLOW GPM Reopening Differential
51. ng 18 mechanism could be greased to provide smooth operation From the grease fitting the grease flowed through small cavities that were machined in the pins To insure the pins would not come out of the joints the pins were fitted with a standard 0 3125 inch hard flat washer on one end with the grease fitting and a standard 0 75 inch external snap ring on the other end The lifting mechanism was attached to the chassis by mounting brackets that were made from AISI 1040 Steel There were a total of eight mounting brackets that were made from the steel plate four were welded to the chassis subsystem and four are welded on the lifting surface subsystems The other ends of the lifting mechanism are attached to sliders which allow the ends of the members to slide along the tracks made on the chassis subsystem and the lifting surface subsystem The sliders were made of the same material as the mounting brackets The tracks of the sliders are able to be greased allowing the sliders to move through the range of motion easily The ends of the lifting mechanisms which are attached to the sliders have two steel stabilizers attached between the top and bottom sliders These braces keep the top and bottom sliders in the same position which keeps the lifting mechanism from getting in a bind where it will not want to operate smoothly The braces are bolted to a small steel block the block separates the stabilizers so one brace 1 on top of the track and one br
52. ng maximum force on the hydraulic cylinder Figure 4 shows 22 maximum force with respect scissor position occurs when the Jack 15 fully lowered The load position on the platform may also affect the load A load that 1s off center by more than the recommend 25 of the total length or width may produce loads greater than designed for A load higher than designed for may cause a failure of the hydraulic cylinder hydraulic lines or hydraulic pump force vs angle length height inches 2 ram lentgh vs angle table height vs angle angle scissor Figure 4 Cylinder Force Ram Length Table Height vs Scissor Angle 23 3 5 Safety NPTF PORT L P MIN CLOSING FLOW Figure 5 2000 Safety Velocity Fuse 2 3 5 1 Technical Description Several considerations had to be met when designing the safety of the belly pan jack The following are considerations allowing the operator to be able to operate the belly pan jack from a safe distance 1f needed full control of the jack must be maintained by the operator and the operator must be protected the event of a loss of pressure causing the jack to collapse To achieve these several items had to be used in conjunction with each other A velocity fuse to prevent the jack from collapse in the event of sudden loss of hydraulic pressure a flow regulator to provide more control to the downward motion of the
53. ngineering Top Front Back Bottom E m 6 s ori LONGOYd 59001 Ad 2000 Technical Manual This manual includes a complete technical description of each subsystem of the jack Refer to this manual before servicing or performing maintenance to the jack Table Contents hupu 101 102 102 Chassis Assembly Drawing 103 C o O 103 Caster Wheels 104 I Jl u toa Q apana aT 104 Wa I EE D 105 ttis N Parts 105 P 106 Slider Guide Ni Chan toma da ea N _______ __ ____ 106 Slider Guide Mechanism tud tado denos eased wien odios tud eadera deos add uoles cod eade ahi 106 Slider Guide Mechanism Assembly Draw iti a uuu dace S Q eue oon 107 TOPS NJEE OMA 107 Pop Slider Crude Parts qu P nu ESSE EES E 107 BOOS TP 107 bottoinhger Gude E E 108 108 Power SystemoPatte ua u a 109 Power syste
54. ois by the client Some of the hard ware needed for the jack like the grease fittings washers bolts nuts and cylinder pins were purchased from Rural King in Carbondale Illinois the hydraulic hose and fittings from Royal Brass and Hose in Benton Illinois Several parts were also purchased from the internet like the pump which was purchased from EBay Other parts were ordered from the internet For example the external snap rings were ordered from mcmaster com the velocity fuse and flow regulator from caster wheels from hamiltoncaster com and the cylinder from surpluscenter com The build of the prototype was not outsourced and the members of team 56 provided all the labor required labor The special tooling needed such as a lathe mill band saw belt sander and drill press was provided by Tim Attig and the MEEP machine shop at Southern Illinois University Carbondale The other tooling such as the grinder MIG welder and acetylene torch were provided by the client Gibbs Construction The cost to outsource the construction of one belly pan jack was provided by Chuck Evans at DMS Welding and Machine 1 37 Table 5 Cost to Implement 2000 Lifting Mechanim 1 x 2 x 3 16 wall thickness 8500 Rectuangular Tubing for Members 45 10 1 125 8500 Pin Stock for Bushings 8 76 3 4 8500 Pin Stock for Pins 8 33 3 4 External Snap Rings for Pins 6 00 1 4 Grease Zerk for Pins 3 50 5 8 Washer for Pins 3 20
55. s On Hand 1 External Snap Rings for Pins 2 00 3 4 Washer for Pins On Hand Power 3 Bore 12 Stroke Hydraulic Cylinder 87 95 3200 psi Air over Hydraulic Pump 300 00 1 8 AISI 1040 Steel Plate for Pump Mounting 1 3 8 Velocity Fuse 24 04 3 8 Flow Regulator 18 72 1 x 5 Cylinder Pins 6 00 Hydraulic Fluid 2 910 00 3 8 Hydraulic Hose with 90 and Straight Fittings 30 00 92 1 Tooling Lathe 1 On Mill 1 Band Saw 1 On Grinder 1 On Belt Sander 1 On Hand Drill Press 1 Welder 1 Acetylene Torch 1 Miscellaneous Shipping of Steel 100 00 Shipping of Pump and Cylinder 37 80 Shipping of Casters 60 00 Shipping of Velocity Fuse and Flow Reeulator 12 39 abr 290hs Total Costof Prototype 15100 2000 Total Cost of Contracted Prototype 4 766 84 38 6 0 Implementation Schedule If the prototype of the designed belly pan jack were going to be reproduced the implementation schedule should be followed The design of the jack is rather complex and requires lot of machining for custom made parts If the build was to begin June 1 2011 the first week should be spent acquiring and ordering the parts listed 1n Table 5 Item Cost Breakdown The build could be started the following week 1f just one person were construct the project it would take approximately thr
56. sliders and possibly cause binding in the lifting system The second is in severe over loading the lifting ram mounting point could break and allow the load to be dropped however the chassis was designed so that in this mode of 15 failure there 1 substantial bracing behind the mount point which would keep the ram from completely escaping the chassis and not allow the load to completely drop The third mode of failure would be if a wheel failed to support the load This would make the belly pan jack unstable and unable to be moved because of the low ground clearance the chassis will settle to the ground before the center of gravity moves outside of the footprint of the chassis The immobility of the belly pan jack will not cause a hazard and the jack should be able to be unloaded and repaired safely 3 2 4 Parts List Table is a parts list of the chassis of the BPJ 2000 a complete parts list with detailed drawings 15 located in Appendix 16 Table 1 2000 Chassis Parts List ITEM QTY PARTNUMBER DESCRIPTION 1 CON BW N N N P PP P P P P P P PB N P O 2 PP P N N N P P N L N N C 2 C 3 C 4 C 5 C 6 C 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Narrow chassis Side chassis Plate Tab Caster mount outside Caster Top plate Caster Wheel Cylinder Bracket botto
57. t Side Yoke Top Yoke Handle Pipe Tow Ring Handle Bolt andle Nut andle Grip aster Mount Outside C10 LC 2 4 5 6 7 8 9 c EE NN ND Chassis Maintenance The chassis of the Jack requires very little maintenance The only service point the chassis 15 the caster wheels The caster wheels are equipped with ball bearings and should be greased after 8 hours of continuous service 102 Chassis Assembly Drawings Caster Wheels 103 Caster Wheels Parts list PARTS LIST PART NUMBER DESCRIPTION Caster Wheel ANSI 18 22 1 1 2 wide Plain Washer Inch Type 9 3 18 21 1 1 2 Regular Helical Spring Lock Washers Inch Series TY 4 2 I 16 ANSI B18 2 1 1 2 13 UNC Heavy Hex Bolt 1 25 16 i 5 16 ANSI 18 2 2 1 2 13 Hex Nuts Inch Series Hex Jam Nut Handle Parts List Description 104 Lifting Mechanism Lifting Mechanism Parts List PARTS LIST ITEM PART NUMBER Slider Base Short grease pin 105 Maintenance The lifting mechanism has a substantial amount of pivot points that are all equipped with grease fittings These pivot points should be greased after 8 hours of continuous service Special attention should be directed to the path in which the feet of the lifting mechanism slide This path should be checked often to ensure that 15 clear of
58. t correspond to the variables in the table above 79 Once all of equations had been developed they were put in matrix form and the variables were solved for using Microsoft Excel The following figures show the spread sheet that was used to calculate the forces in the members The variables w a b x and 0 are design parameters so an initial guess had to be taken and then the forces could be solved for These variables were put into the Excel spread sheet so they could be changed and different combinations of the design parameters could be used to optimized the parameters and find what combinations gave the best results 80 26452615 01515054 3 12506 lt degrees 0 174533 lt radians Fa 16552 3182 Fz 594518284 Matriz Fx Fs Fs Fr Fr F 2 6047 14 7721 0 0 Fs 25000 1 1 0 Fa 246 19 1 0 0 1 0 0 z b 472 14 77216 12500 1 1 0 Fs 54513 0 0 0 1 1 0 0 Fs elre 197721 0 0 7 088 Fe 43561 1 1 0 0 3488 Fe 1653 8 1 1 0 0 0 0 0 0 9372 Inverse of Matriz Fs Fs Fs Fr Fr F 5 13 0 192 2 83564 0 5 0 19196 0 0 F 1692 0 03385 0 5 0 08916 0 03385 0 0 0 3766 0 152 478881 08444 03248 01322 1 Faz 6981 0 03385 122703 0 21636 0 08306 0 0452 1 0 13 0 19196 2
59. t up Hook up for single acting cylinders PUMP AIR a Reservoir use with Cap Usable Oil Port Prod Wt Cyl Type Ibs Single Acting Base model pump with high density PA50 40 120 105 98 Ya NPTF 14 2 polyethlene reservoir Single Acting except has metal reservoir PA50M 40 120 105 98 Js NPTF 16 2 Single Acting 50 except has 12 foot remote control 40 120 105 98 Ya NPTF 18 5 Single Acting except has metal reservoir PASORM 40 120 105 98 NPTF 20 5 Single Acting except has 2 gallon reservoir PA50R2 40 120 2 454 NPTF 28 5 Single and except designed to operate either PA50D 9504 40 120 105 98 Ya NPTF 184 Double Acting single or double acting systems 3 way Valve function Advance Return 4 way Notes Air inlet port 1 4 NPTF Requires 20 cfm at 100 psi shop air pressure at the pump 113 Valve Specifications NPTF PORT DESCRIPTION AN IN LINE 90 ELBOW SWIVEL VELOCITY FUSE WITH AN NPTF OUTLET PORT THAT PROVIDES FULL LINE SHUT OFF IN THE EVENT OF A LINE FAILURE OPERATION A FLOW BELOW THE SPECIFIED CLOSING FLOW IS ALLOWED FROM 1 TO 2 FLOW ABOVE THE SPECIFIED CLOSING FLOW FROM 1 TO 2 IS ASSUMED TO BE A LINE FAILURE AND IS BLOCKED FLOW FROM 2 TO 1 PASSES THRU THE CONTROLLING ORIFICE BUT IS UNCONTROLLED CLOSING FLOW TOLERANC
60. this product 1s rather maintenance free The only item that will need attention regularly is the level of fluid in the reservoir Check the hydraulic fluid level after 8 hours of continuous operation Safety System The safety system of this product consists of a hydraulic flow regulator and a velocity fuse The flow regulator and velocity fuse were purchased from Vonberg Valve INC The valves were special ordered from Vonberg to match this application A complete technical description of the regulator and fuse are located in the appendix of this manual 109 Platform System J NJ o NS 9 Platform System Parts List Parts List ty Screw Adjuster Threaded Rod Platform Maintenance The platform of this product has four pins which are equipped with grease fittings The threaded rods that allow the platform to tilt are lubricated with 80 90W gear lube These areas should be serviced after 8 hours of continuous operation 110 Service Charts Chassis Service C QTY Discription Interval 8 Grease Fitting 8 Hours rease Fitting o8 rease Fitting Hours rease Fitting Hours 111 Platform Service Caster Wheel Service Service Location Discription Interval 8 GreaseFitting 8 Hours rease Fitting S 8 rease Fitting Hours rease Fitting 8 Hours 112 Pump Specifications Typical Se
61. to be a good distance from the jack at all times Due to the large caster wheels and the handle the belly pan jack moves very easily across the shop floor even when fully loaded The grease able pins that where precision machined allow the jack to raise and lower very smoothly while maintaining a constant speed Due to time restrictions not much strain testing of the belly pan jack has been performed However one test that was performed on the belly pan jack was that the Jack was tested to carry its designed load The belly pan jack was loaded with 2000 Ib and the jack was easily able to raise and lower the load Even though extensive actual strain testing has not been done on the belly pan jack yet several simulations were made with the modeling software Autodesk Inventor Figure 8 shows the total displacement created in the various parts of the belly pan jack when loaded to with 2000 Ibs The maximum deformation occurred on the far right end of the lifting surface with a value of 0 31 inches This deformation is not much considering the overall height of the jack 31 Figure 8 Total Displacement with 2000 Ib Load The next figure Figure 9 shows the stress that was produced in the parts of the Hftine mechanism lifting surface and chassis From Figure 9 it can be seen that the stress in the members is very low and the maximum stress occurs in the pins and cylinder mounts where there are high stress concentrations 32 Fi
62. will be used Three main considerations were taken into account when the lifting mechanism was being designed The design considerations were that the mechanism had to collapse fold down to an overall height of 18 inches to accommodate machinery with low ground clearances extend to a height of 55 inches to accommodate machinery with high ground clearances and the 12 direction of travel of the lifting surface that the mechanism would provide The scissors type lifting mechanism was eventually chosen because it met all of these needs Like the lifting mechanism only a couple of considerations were taken into account when it was being designed The main design consideration was that the lifting surface be able to accommodate machines with various shapes and sizes of belly pans This was accomplished by designing the lifting surface to be able to tilt in two directions Once all other subsystems had been designed the safety subsystem was designed The main design consideration for the safety subsystem was to keep the jack from suddenly collapsing if the power system were to fail This consideration was met by connecting a velocity fuse to the cylinder In the event that the hose were to rupture the velocity fuse would close shutting off flow because the flow rate of fluid from the cylinder would be high enough to trip the fuse 3 0 Subsystem Description 3 1 Subsystems Introduction There are five major subsystems of the design

final design report - Southern Illinois University

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