Boom Plate Loader
Sponsored by:
Executive Summary:
JLG industries is the world's leading
manufacturer of aerial work platforms such as the one pictured above. To
manufacture the booms for these machines, JLG welds four pieces of steel plates
simultaneously to form a rectangular cross-section. The average dimensions of
the steel plate used in the boom assemblies are 20 ft. x 12 in. x 1/4 in. The
current method of loading the plate onto the machine is very difficult, time
consuming, and relatively unsafe. The current process requires unloading of the
steel plates from the racks they’re stored in and placed on a work table to
orient them into a position where they can then be lifted and loaded onto the
welding machine. This current process is very time consuming and limits the
production rate of welded booms that can be achieved. There are also many
safety hazards within this current process that need to be eliminated; for
instance, they have unexpectedly had the steel plates fall from their current
lifting technique, which could severely injure personnel. JLG seeks the design
of a new loading device that has the capability to remove all the boom plates
from their storage rack and place them directly onto the welding machine in the
correct orientation safely and efficiently. This will eliminate the middle step
in the current technique and result in a more efficient process.
Solution Goals:
The structure
must be able to lift and carry four steel plates of various dimensions and
weights from a holding rack to a welding machine approximately 15 feet away in
two trips. The plates vary in weight from 120 to 367 lbs and vary in
length from 14 to 19 feet.
The device must
be able to connect to a single overhead hoist hook.
The structure
must be safe and stable.
Costs must be
kept to a minimum.
The Solution:
Design Specifications:
Total Length = 10 feet
Total Weight =
510 lbs
How It Works: (See Pictures Below to Help Illustrate the Boom Plate Loader's Operating Steps)
First Trip to the Welding Machine
The bottom steel plate of a boom model is attached to the two center C-clamps.
The whole structure then lifts the single steel plate from the rack via the electrical hoist attached at the top, and the hoist moves the entire assembly to a position over the welding machine.
The two magnets hanging from the middle beam are attached to the side of the plate, and the C-clamp attached to the winch is attached to the top of the plate.
The first two C-clamps that were attached are now removed.
The electric winch is now lowered, which inverts the plate horizontally.
The bottom plate is then fixed into the welding machine.
The boom plate loader is then returned to a position over the rack via the overhead electric hoist.
Second Trip to the Welding Machine
The four C-clamps on the outer beams are connected to the top of the two side boom plates and the C-clamps on the middle beam are connected to the top of the top boom plate.
The whole structure then lifts the three steel plates from the rack via the electrical hoist attached at the top, and the hoist moves the entire assembly to a position over the welding machine.
The Chains are then moved via the trolley system located on the bottom of the structure to offset the two side plates from the top one so that the two side plates can be lowered into the welding machine. The distance each trolley needs to be moved is model dependant. This distance varies between each model due to the different weights of the plates and the resulting moment that must be countered.
The two sides plates are then lowered and secured into the welding machine and the C-clamps attached to them are removed.
The single top plate of the boom is now inverted horizontally and
lowered into the welding machine in the same way that the bottom boom plate was
that was previously discussed.
More Pictures:
Click on the Links below to view more pictures of our boom plate loader. The Pictures also contain illustrations that help explain these Solid Works drawings.
Pictures Without Plates Attached
Side View
Top View
Random Isometric View
Short Side View
Side View
Random Isometric View
Random Isometric View
Pictures With Plates Attached
Isometric View
Bottom View
Random Isometric View
Top View Close Up
Side View
Pictures With Plate Attached in Horizontal Position
Short Side View
Isometric View
Picture with Plates Offset
Side View
Other Data:
Cost Analysis
Weight Analysis
Color Code For Spring Loaded Quick Release Pins -
This gives the location needed to lock the chains for the different model booms.
The color coded system matches the colors of the pin holes located on the
assembly.
Faculty Coach: Dr. Stephen Copely
Team Members: Darren Mellott, Ben Ciotti, Mike Dobo, and Scott Seprish
Date: Spring 2003
Darren's Resume
Ben's Resume
Mike's Resume
Scott's Resume