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The following work has been done in an effort to find the optimal design of an engine hoist. Using an engineering model, the initial optimization was done with the goal of minimizing the overall weight of the hoist. Subsequently, a microeconomic model was created to re-optimize the design problem, maximizing profit in production. To further validate the economic model, a survey was given and conjoint analysis used to determine attribute elasticities. The attributes that were considered were those deemed to be the most important to potential consumers. These include the maximum feasible load capacity, the maximum height that the hoist can lift, and the price. Finally, three product families were established. The objective of each of the models was weighted and combined to give an overall score. This combined score was then maximized over different sets of weights using two separate sets of commonality constraints. In conclusion, for the economic model, the outcome of the survey showed that to consumers load capacity and price were the most important of the attributes. It was then found that the maximum profit that could be obtained, taking into consideration the costs associated with production, was $4,278,967 for a hoist that could lift just over two tons to a height of 7.79 feet and would cost $277.
Table of Contents
Table of Contents................................................................................................................ 2 Nomenclature...................................................................................................................... 3 1. Introduction................................................................................................................. 5 1.1. The product design problem ............................................................................... 5 1.2. Product development process ............................................................................. 5 1.3. Design Requirements .......................................................................................... 6 1.4. Product decisions from the design phase ............................................................ 7 1.5. Design requirements that can be quantified........................................................ 7 1.6. Design requirements that can be quantified using engineering analysis ............ 7 2. Engineering Design Model ......................................................................................... 8 2.1. Design optimization problem.............................................................................. 8 2.2. Analysis model.................................................................................................... 9 2.3. Optimization model in negative null form........................................................ 11 2.4. Optimization results .......................................................................................... 11 3. Model Extension: Microeconomics .......................................................................... 12 3.1. Competitors....................................................................................................... 12 3.2. Maximization of profit...................................................................................... 15 3.3. Results............................................................................................................... 19 4. Model Extension: Marketing .................................................................................... 19 4.1. Market size........................................................................................................ 19 4.2. Determining betas ............................................................................................. 20 4.3. Linearized demand function, Qm ...................................................................... 22 4.4. Comparison of elasticities and intercept ........................................................... 23 4.5. Re-optimization of design decision model ....................................................... 23 4.6. Comparison of results ....................................................................................... 24 5. Product Family Design ............................................................................................. 25 5.1. Market segments ............................................................................................... 25 5.2. Design optimization models ............................................................................. 25 5.3. Separate design optimizations........................................................................... 26 a. Load capacity .................................................................................................... 26 b. Lifting height .................................................................................................... 27 c. Price (operating variable cost) .......................................................................... 28 5.4. Creating Pareto surface with first set of commonality constraints ................... 29 5.5. Pareto surface with second set of commonality constraints ............................. 31 6. Conclusions............................................................................................................... 33 7. Appendices................................................................................................................ 34 5.1. Appendix A: Patent images .............................................................................. 34 7.2. Appendix B: Initial fixed investment and variable cost.................................... 37 Business plan .................................................................................................................... 40 A) Business opportunity............................................................................................. 40 a) Business objective................................................................................................. 40 b) Product description ............................................................................................... 40 c) Market analysis ..................................................................................................... 41 B) Financial data ........................................................................................................ 42
Capital equipment and supply list......................................................................... 42 Breakeven analysis................................................................................................ 43 Pro-forma income and cost projections ................................................................ 44 I) Annual cost ....................................................................................................... 44 II) Net profit after depreciation and taxes.......................................................... 44 C) Supporting documents .......................................................................................... 45 a) Existing patents..................................................................................................... 45 b) Technical analysis and benchmarking .................................................................. 47 8. Slut ............................................................................................................................ 48
a) b) c)
Nomenclature
A a C C0 C1 d F1 F2 F3 F4 G t I h1 h2 h3 h3 l1 l2 l5 l6 l9 lj,e lj,c M2 Mmaxback Mmaxboom Total length of boom Cross section area of tubing Cost Initial fixed investment Operating variable cost per hoist Diameter of hoist tubing (square) Force on boom from the load at edge of boom Force on boom where jack is attached Force on boom where attached to back Vertical force on back where attached to bottom Gravity Thickness of hoist tubing Moment of inertia of tubing Height of boom when jack fully compressed Height of boom when in horizontal position Height of boom when jack fully extended Height of boom when jack fully extended Distance from front edge, on boom, to where jack is mounted Distance from hoist body, on boom, to where jack is mounted Horizontal distance from back top to back were jack is attached Distance along hoist back between top and point of jack attachment Horizontal distance from back top to back bottom Length of the jack fully extended Length of the jack fully compressed Moment on back where attached to bottom Maximum moment in back Maximum moment in boom
r a p
Price of hoist Quantity Thickness of tubing Volume of back Volume of boom Total volume of back and boom Weight load Distance from center axes of tubing to the edge Angle of hoist body form vertical Vector of product attributes Angle between boom position in vertical and maximum height Sum of angles: , , and Vector of attribute elasticities Price elasticity Profit Intercept with quantity axes on demand curve (economic model) Angle between boom when in minimum height position and back (engineering model) Density Maximum stress in the back Maximum stress in back caused by the moment Stress in back caused by the tension Maximum stress in boom Yield strength Angle between boom position in vertical and minimum height
1. Introduction
Figure 1 below shows an example of a standard engine hoist.
1.1.
The intended user of this product is both commercial garages and private at-home mechanics. For these users, the engine hoist should have the following characteristics. These include choosing dimensions that minimize weight so the hoist is easy to move around, but which also maintain the required functionality in weight capacity. En addition the design must have an acceptable range of operating angles to accommodate the change in vertical height required by the user. The product should also fold up into a more compact form and should be easy to operate. Also important is the need for the product to be inexpensive and for the load capacity to be able to be changed by adjusting the length of the boom.
1.2.
Initialization
The company wants to begin producing a product that fills the market demand. The market segment will be commercial garages and the at-home mechanic. The goal is to reach these segments by producing a product that will satisfy the design requirements.
Marketing analysis
The market is for a product that can easily lift heavy loads and fit into tight spaces.
Product definition
Product must be able to support required loads, not exceed a specified size, and be of minimum weight. The product should fold up for space savings in storage, and it should be possible to adjust the length of the boom (and thereby load capacity). The product should also be able to be easily moved around. The operating height should have a sufficiently large range of motion using an existing hydraulic ram. Criteria such as material availability and cost have been applied to the generated ideas. Final design.
General product goals have been established and existing technology examined.
Idea generation
The desired product characteristics have been determined. Concepts that fulfill all basic requirements. Functional design constraints.
Concept evaluation
Design optimization
Design specifications.
Prototype
Does the model work? A model for evaluation, for testing, and for consumer focus groups. How robust is the product? Life cycle durability. Determine warranty issues.
Physical model
Testing
Marketing strategy
Production planning
How the product will be mass-produced, what facilities will be used, who the suppliers will be, and how the product will be distributed.
Sales
The product must be able to lift a specified range of loads. The boom must be long enough to reach and support the load (clearance issues). Using an existing hydraulic ram, the product must be able to move through a
specified range of operating heights. The total weight should be minimal such that it can easily be moved around. The appearance of the product must be appealing. The cost of the produce must be minimal. The product should be able to fold up into a smaller volume for ease of storage and transportation. The load capacity of the hoist should be able to be changed by adjusting the length of the boom.
1.4.
The design phase, which encompasses product definition through design optimization, the product decisions that can be made include: Topology Load capacity Appearance Size (in use) Ability to move around Durability Manufacturing considerations
1.5.