Project Overview

Project Introduction

Our Senior Design team was tasked with creating a mechanism or device that would be able to help Altech employees lift three components that have to be installed on their medium duty chassis truck.

The photos below provide a more detailed view of the parts being installed under the medium duty chassis lift at Altec.

Pump

PTO

Extension Shaft

These three parts consist of the shaft, PTO, and heat pump. This photo was taken on the Team's first visit to Altec in Elizabethtown, KY.

Problem Background:

Workplace injuries are a serious concern for businesses, particularly in industries that involve manual labor and the handling of heavy equipment. In the United States, the cost of workplace injuries reached $167 billion in 2022 alone, according to the National Safety Council (National Safety Council, 2022). These costs include medical expenses, lost productivity, and compensation claims, which can significantly impact a company’s reputation, profits, and ability to hire employees.

In manufacturing, many of these injuries occur during the assembly process—especially when workers are required to handle heavy or cumbersome parts. For Altec Industries, one such risk occurs during the final step of assembling their medium-duty chassis, where workers manually install heavy components—specifically the power take-off (PTO), pump, and extension shaft—underneath the vehicle.

Altec faces a significant challenge during the installation of these three heavy components. Workers must lay on a car creeper underneath the chassis to position and install the PTO, pump, and extension shaft, all of which can weigh up to 85 pounds. Not only is this physically demanding, but it also presents a high risk of injury. Workers must lift these parts above their heads in a confined space while trying to avoid obstructive cables, bolts, and other pieces of equipment. The limited range of motion in this position—combined with the repetitive nature of the task—can lead to strain injuries and long-term musculoskeletal damage.

Our Design Solution:

The proposed solution is a mechanical scissor lift mechanism, with a sturdy base frame, transport wheels, and an adjustable cradle to hold the component being lifted and move it to the desired location. The device is primarily made from steel to ensure the device can withstand a force of over 85 pounds while remaining economical.

The lift will be built on a solid base frame made from 2-foot-long carbon steel rails and plates. This sturdy frame will provide a strong foundation to support the mechanical lift. The frame will also include bearing housings and grooves to allow smooth vertical movement.

The lift will use a mechanical scissor lift design, powered by an Acme screw system. This ensures that the lift can move up and down without slipping, which is crucial for safety. The Acme screw mechanism will provide precise control over the vertical movement of the lift.

The lift will be equipped with transport wheels, making it easy to move the device to the desired installation location. The wheels will have locks, ensuring that the device remains securely in place during operation.

The cradle of the lift will be adjustable to accommodate the different components—PTO, pump, and extension shaft. The cradle will be designed to fit the specific shape of these components, ensuring a secure and stable lift. It will also allow the components to be maneuvered around obstacles like cables and bolts. The cradle will be made from polyester webbing which has a breaking strength of 1,200 lbs. The heaviest component weighs 85 lbs., so the webbing’s strength will far exceed the needed capabilities to ensure the webbing lasts over multiple uses every day of the week.

Reference(s):

National Safety Council. (2022). Work Injury Costs. Retrieved from National Safety Council: https://injuryfacts.nsc.org/work/costs/work-injury-costs/

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