P17708: Rochester SportNet Improvements
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Preliminary Detailed Design

Table of Contents

Agenda

  1. Key Questions
  2. Engineering Analysis
  3. Feasibility Analysis
  4. Drawings
  5. Bill of Materials
  6. Test Plans
  7. Design
  8. Risk Assessment
  9. Plans for Next Phase

Key Questions

Entering the Phase

Tilt 'n Store

During/Exiting the Phase

Engineering Analysis

Platform Analysis

How should the platform be designed?


Method:

  1. Benchmark (to available wooden deck designs)
  2. Research (design standards and design professionals)
  3. Analysis (Solidworks analysis)


Schematic:
See CAD model below with annotations.

Overall dimensions: 13'4

Overall dimensions: 13'4" x 12' x 6'6"


Analysis:

  1. Free standing
  2. Constrained by the wall in 3 directions, so trusses needed for 4th direction
  3. Must be able to support the stairs and elevator
  4. Internet research on deck design; assuming Southern Pine, 2"x6" joists that are 7'7" long are allowed a 24" span.
  5. Assume an over design method to support heavy loading; Southern Pine, 2"x6" joists that are 5'5" long with a 10" span
  6. Pine Bending strength approximately 1438 psi (dry)
  7. Pine Compression strength approximately 1200 psi (dry and parallel to grain)


Comments:

  1. Subject matter expert commented that platform construction may require a building permit
    • City of Rochester has application process
    • Permit cost $100 for current design
    • Required to submit drawings and schematics for approval
    • Required to submit contractor proof of workers compensations (if a contractor is used)
  2. Subject matter expert suggested passing design by a home improvement store and/or a building inspector

Stair Analysis

How should the stairs be designed?


Method:

  1. Benchmark (to available wooden stair designs)
  2. Research (OSHA requirements)
  3. Analysis (Solidworks analysis)


Schematic:
See CAD model below with annotations.

Hand Rails not Shown

Hand Rails not Shown


Analysis:

  1. To be mounted to a sliding system of some sort (similar to the slider in a drawer, or a track system like a garage door) and the base shall have wheels attached in order to move stairs from side to side
  2. Must adhere to OSHA standards; 50 to 75 degree angle from horizontal may be used if:
    1. Capable of supporting at least 200 lbs at the tread center
    2. Have open treads at least 4" in depth and 18" in width, with uniformly spaced vertical rises between treads of 6 to 9.5"
    3. Hand rails from tread surface shall be 30"


Comments:

  1. Determining sliding mechanism and wheel support will be a high risk item moving forward
  2. Performing stress analysis in Solidworks will help in determining chosen design

Tilt N' Store

An analysis of some of the key questions for the Tilt N' Store can be found here - Tilt N Store Analysis

The MATLAB code surrounding the Tilt N' Store analysis can be found here - Tilt N Store Analysis - MATLAB


Chain Hoist:

The video of Brady testing a chain hoist on campus can be accessed here - Chain Hoist Video

Rate of Movement

Rate of Movement

Feasibility Analysis

Lifting Analysis - NIOSH

Are the current lifting methods safe? If not, what are the recommended safe lifting limits?


Assumptions:

  1. Each of the tricycles weighs 50 lbs
  2. Each of the blue crates weighs 100 lbs
  3. Lifting the tricycle was assessed as a two-handed task due to the limitation of the NIOSH lifting equation


Analysis:

NIOSH Calculation - Lifting Tricycle onto Pulley

NIOSH Calculation - Lifting Tricycle onto Pulley

NIOSH Calculation - Lifting Blue Crates into Truck

NIOSH Calculation - Lifting Blue Crates into Truck


Conclusion:


The NIOSH Analysis spreadsheet can be accessed here - NIOSH Analysis

Lifting Analysis - Liberty Mutual Tables

Are the current lifting methods safe? If not, what are the recommended safe lifting limits?


Assumptions:

  1. Each of the tricycles weighs 50 lbs
  2. Each of the blue crates weighs 100 lbs
  3. Lifting the tricycle was assessed as a two-handed task due to the limitation of the Liberty Mutual Tables
  4. Each of these tasks is only performed once in an 8 hour shift


Analysis:

Liberty Mutual Analysis

Liberty Mutual Analysis


Conclusion:


The Liberty Mutual Tables can be accessed here - Liberty Mutual Tables

OSHA Standards

Is the current facility violating OSHA standards? Which standards are being violated?


Analysis:

Standard Description Violation
1926.1053(a)(1)(ii) Ladders shall be capable of supporting at least four times the maximum intended load. The current ladder can barely support the weight of the average person, which doesn't even consider trying to bring equipment into or out of the loft. Both situations are nowhere near four times the intended load.
1926.1053(a)(2) Ladder rungs, cleats, and steps shall be parallel, level and uniformly spaced when in use. The current ladder has rungs which aren't all parallel, level or uniformly spaced.
1926.1053(a)(11) Ladder components shall be surfaced so as to prevent injury to an employee from punctures or lacerations, and to prevent snagging of clothing. The current ladder is non-lacquered wood, therefore an employee is likely to get splinter and/or other lacerations and punctures.
1926.1053(b)(1) When portable ladders are used for access to an upper landing surface, the ladder side rails shall extend at least 3 feet above the upper landing surface; or, when such extension is not possible because of the ladder's length, then the ladder shall be secured at its top to a rigid support that will not deflect and a grasping device shall be provided to assist employees in mounting and dismounting the ladder. The current ladder is not long enough to extend 3 feet pas the edge of the loft and there is not currently a way to secure the ladder, nor is there a grasping device available for use.
1926.1053(b)(15) Ladders shall be inspected by a competent person for visible defects on a periodic basis and after any occurrence that could affect their safe use. The current ladder could not pass inspection for visible defects.
1926.1053(b)(16) Portable ladders with structural defects shall be withdrawn from service until repaired. There are several structural defects to the current ladder, including small cracks, areas of splintering wood, and is visibly unsteady. Therefore it should be repaired or replaced.
1926.1053(b)(22) An employee shall not carry any object or load that could cause the employee to lose balance and fall. The current ladder situation does not allow for the safe loading or unloading of equipment from the loft.
1910.23(c)(1) Every open-sided floor or platform 4 feet or more above the adjacent floor or ground level shall be guarded by a standard railing on all open sides except where there is entrance to a ramp, stairway or fixed ladder. The loft currently has no guardrails or protective railings on the open side.
1910.23(e)(1) A standard railing shall consist of top rail, intermediate rail, and posts, and shall have a vertical height of 42 inches nominal from upper surface of top rail to floor, platform, runway or ramp level. The top rail shall be smooth-surfaced throughout the length of the railing. The intermediate rail shall be approximately halfway between the top rail and the floor, platform, runway or ramp. The ends of the rails shall not overhand the terminal posts except where such overhang does not constitue a projection hazard. The loft currently has no guardrails or protective railings on the open side.


Conclusion:


The OSHA standard 1926.1053 can be accessed here - 1926.1053

The OSHA standard 1910.23 can be accessed here - 1910.23

Truck Feasibility Analysis

Is there a solution that can meet Mike's requirements and be easily implemented by the team?


Assumptions:

  1. Need to eliminate the task of lifting heavy items into the back of the truck
  2. Need to consider options that reduce the need to crawl into the back of the truck to move equipment


Analysis:

public/Photo Gallery/Truck Feasibility.JPG

public/Photo Gallery/Truck Feasibility.JPG


Conclusion:


The Truck Feasibility Analysis can be accessed here - Truck Feasibility Analysis

Drawings

Cubbies

Proposed Design

Proposed Design

Platform

Proposed Design

Proposed Design

Tilt 'n Store

Proposed Design

Proposed Design

Elevator

Proposed Design

Proposed Design

Bill of Materials (BOM)

Bill of Materials & Budget (Rev. 1)

Bill of Materials & Budget (Rev. 1)


The Bill Of Materials spreadsheet can be accessed here - Bill of Materials

Engineering Requirements

 Engineering Requirements (Rev. 3)

Engineering Requirements (Rev. 3)

Test Plans

Engineering Testing

The follow test plans were formed to ensure the final design meets all engineering requirements after all the proposed designs have been implemented.
  1. Cycle Time Analysis
    • We plan on timing the different processes for accessing equipment and comparing the old times with the new. This will allow us to see the percentage of improvement in loading or unloading, as well as accessing the equipment.
  2. Facility Measurements
    • Measurements of the space within the storage facility, including amount of space being utilized and square footage added will allow for a quantitative expression of the improvements made
  3. Customer Survey & Satisfaction
    • Customer and stakeholder satisfaction with the implemented design will be the best indicator of project success.

Ergonomic Testing

  1. Below is a list of OSHA standards which are currently being violated, the plan is to continue to add to the list as the proposed design becomes more detailed. At the end of the project, once all the construction is completed, we will review the list and ensure we have met all related OSHA standards. If they have all been met then both the storage facility and employee safety has been improved.
    • OSHA standard 1926.1053
    • OSHA standard 1910.23
  2. Once the new designs and layouts are finalized we will analyze the new lifting processes and compare the new lifting indices with the previous lifting method lifting indices. This will allows us to quantitatively show how much of an improvement has be made in employee safety.

System Design

Current vs. Proposed Layout (Rev. 2)

Current vs. Proposed Layout (Rev. 2)

Side View of Proposed Layout (Rev. 1)

Side View of Proposed Layout (Rev. 1)


The Facility Layout can be accessed here - Facility Layout

Risk Assessment

Risk Management (Rev. 3)

Risk Management (Rev. 3)

Risk Management (Rev. 3, Zoomed)

Risk Management (Rev. 3, Zoomed)


The Risk Management Spreadsheet can be accessed here - Risk Management

Plans for Next Phase

Phase 4 Schedule

Phase 4 Schedule

Deliverable Completion Plan (Rev. 2)

Deliverable Completion Plan (Rev. 2)

Team Member Phase 3: What did I actually do? Phase 3: What did I learn? Phase 4: What do I plan to do?
Brady Hawkes
  • Helped Design the Tilt N’ Store
    • Conducted a shear and bending moment analysis for the major components of the Tilt N’ Store
    • Created a hand sketched first draft drawing of the Tilt N’ Store (with dimensions)
    • Researched alternative materials that can be used to construct the Tilt N’ Store
    • Provided a high-level Bill of Materials estimate for the Tilt N’ Store
  • Investigated Designs for the elevator
    • Brainstormed new ideas with the team
    • Performed a simple pulley analysis
    • Conducted a Stress Analysis on the elevator arm
  • Aided in the Chain Hoist Time Study
  • Continued brainstorming ideas for loading and unloading the truck
  • Worked with to create an initial budget that addresses all subsystems within the project
  • With so much attention on the Tilt N’ Store we need to make sure we are giving each one of our other high priority designs the time they need.
  • The best Subject Matter Expert for the platform is probably a building inspector.
  • The MECE Machine Shop has a lot of raw materials left over from other projects that may help the team reduce costs.
  • Partially optimize some of the major components on our subsystems (our Subject Matter Expert said we shouldn’t bother with fully optimizing our designs) (15 Hours)
  • Update and Finalize the Bill of Materials for the project (6 Hours)
  • Begin ordering the materials we need for MSD II (1 Hour)
  • Create Part Drawings for each our subsystems (10 Hours)
  • Meet with Subject Matter Expert on the Platform (5 Hours)
  • Work with Peter to verify all analyses were executed correctly
  • Ensure all designs are properly documented for easy reference in MSD II (5 Hours)
  • Assist Team in preparing for the close of MSD I (2 Hours)
  • Analyze the Tilt N’ Store for possible buckling and include Axial Loading (3 Hours)
Cali Smith
  • Actively participated in the creation of the budget for each subsystem and completed it on schedule (by Oct 19th).
  • Updated EDGE with documentation and pictures as they were completed.
  • Helped to complete the NIOSH lifting feasbility analysis, and determined how safe or unsafe the current lifting methods are.
  • Researched OSHA standards for portable ladders in order to help Mike with writing the grant.
  • Researched OSHA standards for lofts and platforms in order to help Mike with writing the grant.
  • Created a side view of the layout to help provide additional, visual information about our proposed designs.
  • All current lifting methods were confirmed to not be safe for any employees to complete on a regular basis without likely back injuries.
  • Creating a budget without a completed detailed design is difficult and requires a large amount of estimating and guess work.
  • Mechanical engineering analysis requires a much larger amount of math and technical thought process, reminds why I am glad I choose my major.
  • Update EDGE documentation and Detailed Design page as needed to fit the teams needs
  • Assist the team with researching and providing more details for each of the subsystem designs
  • Research more OSHA standards in relation to the new design details
  • Update the proposed layout with improved or new design specs.
  • Assist the team with creating a plan for MSD II.
Peter Larson
  • Created CAD models in Solidworks to show concepts of the platform, stairs, elevator, and Tilt N’ Store
  • Designed platform and stairs
  • Contributed to the creation of a budget and preliminary BOM to our customer by October 19
  • Assisted with statics analysis of Tilt N’ Store
  • Visited subject matter expert for Tilt N’ Store analysis
  • Started learning how to do stress analysis in Solidworks
  • How to model parts and assemblies in Solidworks
  • Focusing on creating a budget and the Tilt N’ Store analysis distracted me from some other high risk items that developed
  • Platform may require a building permit
  • Complete CAD models and necessary simulations in Solidworks
  • Learn how to run necessary simulations in Solidworks
  • Actively participate in team meetings and brainstorming sessions
  • Maintain communication and conversation with customer
  • Update assigned portions of EDGE
  • Address high risk items for stairs and elevator
  • Get platform design approved by necessary individuals
Sarah Harley
  • Worked on concepts for unloading/loading truck
  • Truck Feasibility Analysis
  • Participated in creating Budget
  • NIOSH lifting analysis
  • Liberty Mutual Analysis
  • List of safety violations
  • Assisted in testing Chain Hoist
  • Assisted in alternative view of layout
  • Created plans for phase 4
  • May not be able to come up with a feasible solution for the truck
  • We need to talk to a building inspector
  • Assist in revising the BOM as necessary
  • Perform Ergonomic evaluations on elevator
  • Feasibility Analysis on loading/unloading truck solutions
  • Assist in updating drawings and further risk analysis
  • Create purchasing plan and make purchases as necessary
  • Create plans for next semester
  • Assist in updating EDGE


The Schedule and Completion Plan can be accessed here - P17708 Schedule

Individual 3 week plans can be accessed here - Brady, Cali, Peter, Sarah


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