4.

Materials and Design for Manufacturing

4.1 Assembly Details

FIGURE 4.1.1A: Proposed Isolated Assembly

FIGURE 4.1.1B: Actual Isolated Assembly

Components List: Handle Bar (1), Large Cut Tubes (2), Small Tubes (2), Gear Racks (2),
Clamps (4), Cross Beams (3), Caster wheels(4)

36
 FIGURE 4.1.2A: Proposed Handle Bar and Spacers Welded to Large Cut Tubes

FIGURE 4.1.2B: Actual Handle Bar and Spacers Welded to Large Cut Tubes
1. Weld two spacers on each end of the frames
2. Weld handlebar to the rear welded spacers
a. Ensure that the handlebar is centered
3. Insert small tubes into large cut tubes

37
 FIGURE 4.1.3A: Proposed Addition of Caster Wheels

FIGURE 4.1.3B: Actual Addition of Caster Wheels

4. Attach all 4 wheels to the bottom of the frame, one wheel in each corner and at each
center point. Center and drill holes on the frames to attach casters
a. Use bolts and nuts to make attachment

38
 FIGURE 4.1.4A: Proposed Addition of Cross Beam Members

FIGURE 4.1.4B: Actual Addition of Cross Beam Members

5. Weld cross beam members to connect the large cut tubes

39
 FIGURE 4.1.5A: Proposed Addition of Clamp Mounted Bearings

FIGURE 4.1.5B: Actual Addition of Clamp Mounted Bearings

6. Attach and secure mounted bearing on each spacer

40
 FIGURE 4.1.6A: Proposed Addition of Clamp Mechanisms

FIGURE 4.1.6B: Actual Addition of Clamp Mechanisms

7. Mount clamp design sub-assembly
a. Align clamp with the mounted bearing

41
 b. Place the shaft coupled to the motor through mounted bearings and clamp.
c. Attach and secure the motor on the frame

FIGURE 4.1.7A: Proposed Finished Assembly

FIGURE 4.1.7B: Actual Finished Assembly

8. Finished assembly

42
4.2 Material Selection
Telescoping Frame

Objective
The objective of the telescoping frame material is to make it somewhat strong to withstand
deformation and make it light so that it does not add any more fatigue for the operators. Also, it
should be a low cost material to help us stay within the budget.

Potential Materials
For this specific component, there are three types of commonly used materials - aluminum, iron,
and steel. Aluminum is a lightweight material and it is relatively cheap. Iron is a lot heavier than
the aluminum, but it has higher tensile strength which means it can withstand deformation better
than the aluminum. Finally, steel has similar weight as iron and it would make our welding
process easier.

Selected Material
After discussing advantages and disadvantages of three different materials, we chose to use
aluminum, specifically 6063 aluminum, for the telescoping frame. Based on the property table
for 6063 aluminum, it has tensile strength of 195 MPa which is already strong enough to
withstand deformation from external forces. Also, aluminum has the lowest density(2720kg/m3),
while other two materials have a density of 7850 kg/m3 which meets our second objective15.
Furthermore, a 6ft long 2”x2” aluminum tube cost about $95 while a 6ft long 2x2 in steel tube
cost around $145 which greatly helps us to stay under budget if we elect to use aluminum.

For the actual design, we would recommend using steel because it is a lot stronger than
aluminum and welding a steel frame would make the manufacturing process much easier.

For the purpose of strictly constructing a prototype, we elected to use wood instead of
aluminum, as it is readily accessible and incredibly easy to work with. It is not great regarding
tensile strength and deforming from external forces. However, our plans to use wood are to
reflect more of the concept of the design, rather than building a physically robust structure.

43
FIGURE 4.2.1: Property Table of Aluminum26 FIGURE 4.2.2: Aluminum Tubing29

FIGURE 4.2.3: Property Table of Wood32 FIGURE 4.2.4: Wooden 2x433

44
Clamp

Objective
The material for the clamp must have high tensile strength and hardness to overcome any
deformation when undergoing external loads by pulling and pushing the dollies. This also
ensures that the component has high durability for a long period of operation. For this specific
component, we thought that the price is irrelevant since it is one of our key components of our
design.

Potential Materials
For our clamps, three potential materials have been selected - plastic, aluminum, and steel.
Plastic is a cheap material commonly used for smaller prototypes. Aluminum is a material that is
also cheap and malleable. Finally, steel is a strong material and it is the same material as the
dollies themselves.

Selected Material
After discussing advantages and disadvantages of three different materials, we chose to use
steel, specifically S45C steel, for the clamps. Based on the property table for S45C steel, it has
tensile strength of 569MPa which is very high for the component to overcome any type of
deformation experienced with the clamps from the dollies.

For the actual design, we still recommend using steel because we did not choose an alternative
material for our prototype. Steel is an ideal material for use in moving the dollies back and forth.

FIGURE 4.2.5: Property Table of Steel31 FIGURE 4.2.6: Clamp Close-Up30

45
4.3 Mechanisms
Pin Mechanism

It is critical that the position of the telescoping frame is locked in place while setting the
dollies. In order to accomplish this, we needed a mechanism to physically stop the telescoping
rail from sliding in and out of the frame. We decided to use a pin that sits through both a hole in
the outer telescoping frame as well as into the internal telescoping rail to prevent it from moving.
In order to ensure ease of use, we wanted to design a mechanism to place and remove
the pin from its locked position without the need for an operator to bend over and take it out by
hand. Our group investigated two mechanisms, one where the pin motion is driven by a pulley
and the other with a hinge. If we were to use a pin attached to a hinge, the operator would
simply pull a string, run from the pin to the handle bar, and the pin would flip up out of place,
disconnecting the inner telescoping rail from the outer frame. When the operator releases the
string, the pin would then fall naturally back into place. The problem with this design is that
instead of moving linearly up and out, the pin would move circumferentially and therefore would
require larger holes in the frame/ rail to move
freely. Therefore, the system would not be
entirely limited in movement, as the slot in the
frame/rail would need to be larger than the
diameter of the pin. To combat this problem,
we implemented a pulley system, attached to
the outer telescoping frame, so that when the
operator pulls a string attached to the pin and
fed over the pulley up to the handle bar, the pin
moves linearly up and out of place. This way
the diameter of the hole made in the frame/rail
only needs to be as large as that of the pin.

FIGURE 4.3.1: Pulley Diagram21

46
Caster Wheels

Our system relies on its ability to be

maneuvered by the operator with ease. In
order to achieve this trait, a high performing
wheel mechanism must be considered. In our
case, there were two potential mechanisms,
the straight axle wheel and the caster wheel.

Through further investigation we

decided the caster wheel would be the best fit
for our project. Caster wheels provide more
degrees of freedom than the straight axle
wheel. This ensures that the operator can
maneuver the system with ease in any
direction. Caster wheels will be used in the
prototype of the system and are recommended
for use in the actual system.

FIGURE 4.3.2: Caster Wheels Diagram25

Clamp Mechanism

Our system is contingent on the ability to form locking points between certain cross
members of the dollies, using a form of a pressure fit. Two viable solutions presented
themselves, a rotational pressure fit similar to a deadbolt lock, or a translational pressure fit
similar to two pistons closing and opening from opposing sides.

Due to minimal workspace underneath the dollies, our team opted for the rotational
pressure fit for efficient use of space. Our design reflects how our clamps can collapse into our
frame and take up minimal space, compared to how two pistons would need to nearly be level
with the cross member beams of the dollies to
ensure a secure clamp. Aside from saving space,
our rotational pressure fit also ensures a secure
clamp at precise points under the dollies.

FIGURE 4.3.3: Deadbolt Diagram35

47
4.4 Design for Manufacturing
C- Channel Clamp

The ability for our system to clamp onto the

dollies is an essential component in our design. Our
thought process behind the C-Channel Clamp was to
have something that could attach and detach to the
dollies during operation, while ensuring that the dollies
remain secure to our system at all times to move in
unison.

FIGURE 4.4.1: Clamp Mechanism

Close-Up

Our C-Channel clamp design has a profile similar

in shape to that of a Norman Window. This way the
clamp can lay flat onto the frame of our system when it is
in the lowered position and not being used. The rounded
lower portion allows the clamp to rotate up and down
without any interference from the frame. The space
hollowed out of the top provides the perfect amount of
space to encase the rail of the dolly.

FIGURE 4.4.2: Clamp Simulation Fit

The C-Channel clamp will be fabricated in the Makerspace. The general shape can be
achieved through a combination of milling, sawing, and welding. The hole for the driveshaft will
require a drill press.

48
Wiring Harness/Telephone Cord

In order to power the motors on our assembly, we will have wires running through the hollow
telescoping rails of our frame. Because the frame of our system extends and contracts, the
ability for wires to telescope with the frames is critical. Wires cannot be taut or prone to
snapping. In order to prevent this, our group needed to develop a structured method to move
wires consistently with the frames.

We elected to use a telephone cord, as the cylindrical cord is

capable of extending and compressing back into its original
shape. It easily fits into our design, only running in a straight
line underneath our telescoping frame. It only extends 4
additional feet from its initial compressed position, and stays
very close to the tubing preventing any ways for the wires to
get caught and snap.
FIGURE 4.4.3: Telephone Cord
The telephone cord does not itself need to be fabricated in the Makerspace, but any
adjustments to the cord along with our wires between soldering them together and using a drill
to make holes for fish eye wire guides will be done in the Makerspace.

Telescoping Sleeve

In order to adjust cab sizes, our telescoping frame needs to be able to telescope. It also needs
to be able to contain certain components, such as the telephone cord to power the front motors,
and the cabinet rails on which the interior tube slides on.

The sleeves allow the frame to be manually

telescoped. All that needs to happen is the rear
operator releases the pins that are securing the inner
tube. The front operator stands on the cross beam
connecting the two inner tubes, and then the rear
operator can either walk backwards to extend the
telescoping length, or forwards to diminish the
telescoping length.

The shape and installation of this incision ensures that

Minimal interference is encountered, keeping the gear
rack out of the way of the larger telescoping rail. The
incision being made for the gear rack does not affect
the structural integrity of the large telescoping rail.
FIGURE 4.4.4: Telescoping Frame

The telescoping sleeve will be made in the Makerspace. It will be fabricated using power tools to
adhere, L brackets, cabinet rails, and plywood, and also using the saw.

49
5. Prototype Testing
5.1 Test Design
The design testings were done in following order:

1. Weigh the jig prior to initial operation

2. Identify individual(s) that will test the designs
3. Place all required equipment in designated areas
4. Start the timer once individuals and all necessary equipment are in place and prepared
to begin
5. User will move the jig from their starting area and attach their jig to the appropriate dolly
6. Dolly will be moved from designated grid to its final destination where there will be a
target area for all of the dolly’s wheels
7. User detaches their jig from the dolly
8. Jig is returned to its starting point and timer is stopped
9. Annotate any damage or visible wear and tear to the jig and/or dolly after five iterations
10. Compare the time currently required to complete the process to the time for the jig
assembly to accomplish a similar task
11. For systems that require two separate jigs, the user will repeat the process with the
alternate dolly (The time that is the greater of the two will be selected as the time to be
used)

FIGURE 5.1.1: Test Design Setup

50
5.2 Statistical Analysis of Data
TABLE 5.2.1: Test Design Data
Test # Individual 1 Individual 2 Individual 3 Individual 4 Individual 5

1 1:35.59 56.62 1:03.86 1:04.24 54.88

2 1:37.89 1:01.60 40.89 59.58 1:00.05

3 1:01.62 1:17.34 1:34.54 58.05 57.79

4 1:09.45 59.32 58.72 1:14.67 1:09.43

5 1:07.39 50.97 1:06.95 1:16.78 1:08.47

Avg Time 1:18.39 1:01.17 1:04.99 1:06.66 1:02.12

Total average operation time 1:06.26

FIGURE 5.2.1: Histogram of the Test Design Data

Table 5.2.1 shows the exact test data performed five times by five different individuals which
makes 25 testing data in total and Figure 5.2.1 shows is the histogram of those data to aid
visualization. The total average operation time was calculated to be 66.66 seconds with
standard deviation of 12.70 seconds. Most of the data were within the range of standard
deviation except for a few outliers. Furthermore, the number of non-ergonomic movement for
front and rear operators during each test was zero which shows that our design has taken
ergonomics into account.

51
6. Economics/Cost
6.1 General Economics

TABLE 6.1.1: Annual Cost-Benefit Analysis

Item Proposed Design

Initial Cost $428.68

Annual Cost $192.96

Annual Benefit $0

Useful Life(yr) 3

Table 3 shows the annual cost and benefit analysis of the proposed design. The initial cost in
building and implementing our proposed design would exceed our budget limit of $800.
Therefore, we have used the cost for building a prototype for this analysis. Changing the design
parts to higher grade materials will increase the initial cost. The annual cost or annual
maintenance expenses are estimated to be around $193. This value was obtained by assuming
only the motors are being replaced annually. This design is not expected to bring any financial
benefits because it does not dramatically increase the speed of the operation or production of a
cab model. Finally, the design is expected to last for 3 years. After 3 years, the entire design will
need to be built again.

Although the design does not financially benefit the operators, it greatly benefits the operation
process. Unlike the current operation process where operators need to do three tasks at the
same time, usage of this design allows them to focus on one task at a time. Both dollies will be
able to be controlled by one operator while another operator can focus on lowering a cab model.
The design has a handle attached which allows the operator to push and pull easily without
having to bend down or kick the dollies to a right position. These improvements in the operation
process greatly reduces the fatigue of the operators which increases the efficiency of the
operation.

52
6.2 Cost
TABLE 6.2.1: Detailed Cost-Breakdown Analysis
Cost ($)
Order Vendor Parts Quantity (+ shipping Actual Cost ($)
& tax)

1 Amazon Cabinet Rails27 2 $96.62 $96.62

Home
2 2x4 4 Donated $14.00
Depot

Home
3 2x6 2 Donated $17.00
Depot

Home
4 Plywood19 1 $10.73 $10.73
Depot

L-Brackets 2in23 1 2in L-B

5 Lowe’s L Brackets 2.5in22 2 2in L-B $20.29 $20.29
Wood Screws13 1 Screw

Battery16 1 Battery
6 Amazon $101.83 $101.83
DC Motors10 4 Motors

7 Lowe’s L-Brackets 1.5in 1 $10.70 $10.70

L-Brackets 3in24 3 3in L-B

8 Lowe’s $21.90 $21.90
Wood Screws12 1 Screw

9 Amazon Shaft Couplers39 1 $15.00 $15.00

Screw Eye Hooks11,14 2 Scr Eye

10 Lowe’s Compression Springs 1 Spring $15.60 $15.60
2-Hole Pipe Strap1,2 2 Pipe Strap

Ace
11 Telephone Cord9 1 $9.60 $9.60
Hardware

12 Target Retractable Coil 1 13.79 13.79

Telephone Cord9 1 Tel Cord

Ace
13 Audio Cord17 1 Aud Cord $32.85 $32.85
Hardware
Flex Tubing8 2 Flex Tube

Alligator Clip
14 Amazon 1 $24.40 $24.40
Retractable Coil

15 Amazon DC Motors10 2 $32.16 $32.16

16 Lowe’s Wire28 1 Wire Roll $23.21 $23.21

53
Screw Eye Hooks11,14 2 Scr Eye

Total $428.68 $459.68

54
7. Quality Engineering
7.1 Deliverables
TABLE 7.1.1 : Deliverables
Deliverable Date

Feasibility Study Review

10/07/2022
(FSR)

Preliminary Design Review Report

10/21/2022
(PDR Report)

Preliminary Design Review

11/04/2022
(PDR)

Critical Design Review

11/18/2022
(CDR)

Critical Design Review Report

12/02/2022
(CDR Report)

Mock-up Model Presentation 1/25/2023

First Test of the Prototype 3/01/2023

Final Test of the Prototype 3/29/2023

Detail Design Review Report

4/07/2023
(DDR Report)

Detail Design Review

4/12/2023
(DDR)

Prototype Demonstration 4/12/2023

7.2 Safety
Safety of the operators was of the utmost concern when developing this design. One major
objective of this design is to eliminate the need for an operator to be underneath the cab at any
time during the downloading process. This design allows the operators to adjust and set the
dollies to the desired cab position before downloading the cab, lowering the risk of injury by
eliminating the need for operators to manually adjust the dollies while underneath the cab. This
design also eliminates the need for operators to lift the dolly spacing mechanism at any time as
the mechanism uses caster wheels and is easily moveable by the operator with the extended
handle.

55
There are several areas of concern when it comes to safely manufacturing this design. One
area of concern is safety during welding the clamps, handle bar, spacers, and cross beam
members to the frame. In order to avoid any safety concerns, the welder would be required to
follow all safety precautions (NCSU Welder Safety Rules shown in Appendix). Another area of
concern would be the clamps, as they move up and down to attach to the dollies. It is important
to make sure no fingers, hands, or other obstructions are in the way of the gear rack mechanism
or the clamp mechanisms to avoid injury and machine malfunction. Furthermore, proper storage
of the batteries used for the motorized portions of this design and the controller are also a
concern. In order to avoid any problems with mechanism or controller function, all battery
manufacturer safety and storage recommendations should be followed by any users of this
design (Battery Manufacturer Safety and Storage Recommendations shown in Appendix).

Safety of all team members when manufacturing this design is also of the utmost importance. In
order to ensure the safety of all team members during the production of the design, all members
of the group must be certified in their manufacturing roles. Members will follow general shop
safety rules and shop rules for their respective roles (see Appendix for Shop Safety Rules).
Members should be in accordance with the National Society of Professional Engineers Code of
Ethics (see Appendix for NSPE Code of Ethics).

7.3 Impact on society

In the realm of manufacturing, it is extremely important that all facets of the industry are catered
to in order to ensure that the entire system works as efficiently as possible. Some of the most
important entities to this system are the operators working directly with the products being
manufactured. It is extremely important that the needs of these workers are met in order for
them to do their job properly. This project emphasizes the importance of accommodating the
needs and wants of the operators of an industry so that they are put in the best position possible
to succeed. It is extremely important for operators to know that the people they are working for
care about their wellbeing and want to make the conditions that they work in better for them.

By identifying the problem of dolly placement during the Cab Downloading process, Daimler
Truck NA is striving to improve working conditions for their employees. This is impactful
because setting employees up for success increases efficiency in any company. This project is
also impactful because it has a lot of potential to decrease TAC time and increase productivity
on the manufacturing floor.

This project is impactful to the MAE Department at NC State because it emphasizes the
importance of real world experience in an academic setting. Without the collaboration of
external companies, the department would not be able to offer their students the challenge of
solving real problems. The MAE Department is impacted because they gain more insight on
what it is like to work directly with a company and the academic growth that comes with it.

56
The members of this design team were greatly impacted by this project as it gave each member
a chance to apply all they have learned in their undergraduate career to a real world
engineering problem. It also allowed members to learn new skills through training for their
manufacturing roles and implement those skills during the creation of this project.

57
7.4 Ethics
This project was created in accordance with the National Society of Professional Engineers
(NSPE) Code of Ethics and the North Carolina State University (NCSU) Code of Student
Conduct. While creating this project all team members prioritized safety as the first duty of an
engineer is to, “hold paramount the safety, health, and welfare of the public.” 2

As the NSPE Code of Ethics states, “[engineers shall] act for each employer or client as faithful
agents or trustees”.2 The engineers of this project understand that Daimler Truck has entrusted
this group with important company knowledge that should not be shared with those outside this
team or the company. The engineers of this project attest that all designs were original and that
the information showcased in this report is truthful to the best of the team's ability.

According to the NCSU Code of Student Conduct plagiarism is, “the use or close imitation of the
language and thoughts of another and the representation of the other’s work as their own.” 3 All
of the information showcased in this report was created solely by this team and is not the work
of anyone else. All outside materials or knowledge used to support the creation of this project
has been properly acknowledged in this report.
.

58
8. Concluding Remarks
The purpose of this project is to create a design that can be used as a solution to the
problem presented by our sponsor, Daimler Truck, as mentioned in section 1.2. Ultimately, our
design was able to satisfy all the problem statements. The total cost of the prototype was
$428.68, which is under the $800 budget limit and it is designed at a size to fit in the operating
area. The design uses a clamp mechanism which attaches to the lower beam of the dollies to
move both dollies in a one uniform motion. This allows the design to be operated by one
operator with high removability and repeatability while another operator can focus on
downloading the cab. Because our system uses the existing dollies, it eliminates any concerns
regarding the modification of the dollies. The telescoping frames were implemented on the
design which has preset distances to fit various sized cabs. Finally, in order to observe its
performance, several design testings were done. The average operation time was measured to
be about 1 minute 6 seconds with no deformation on the design identified. This proves that our
design maintains the current cycle time of 5 minutes and is durable enough to move dollies.

The main features of special interest for our design are C-clamp channel and telescoping frame.
These two features allow the design to require only one operator to space out dollies depending
on the cab size and move both dollies simultaneously without any non-ergonomic movements
which also complies with Daimler and OSHA safety standards. That being said, the major
advantages of our design is that it can be operated by one operator, moves both dollies as a
one unit, and it has taken ergonomics into account. However, there are still some downsides in
our design. The design is vulnerable to lateral movements and the size is relatively big which
may take up a lot of space when storing. In addition, since we utilize motors for our clamp
mechanism, the battery will need to be checked and recharged before the operation.

Although the design has been completely fabricated and fully functional, there is additional work
we would like to do for improvement if we had more time. The wire that we use for our pin
mechanism is completely exposed which is prone to snapping. More research and observation
could have been done for the reinforcement.

Even though there were many challenges we had to overcome, our team believes this project
gave us an opportunity to apply knowledge we have been learning as undergraduate students
to the actual engineering design problem. This experience will benefit us in making correct
engineering decisions in our future engineering careers.

59
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Appendices
Appendix A: Shop Safety Rules

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Appendix B: NSPE Code of Ethics

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Appendix C: Battery Manufacturer Safety and Storage

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