Hydraulic jack

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Contents 1 Executive Summary 2 Stakeholder Needs 3 Usability Study 4 Assembly 5 Bill of Materials 6 Product Functionality 6.1 Step-by-Step Instructions 6.2 Mechanical Function 7 Design for Manufacturing and Assembly (DFMA) 8 Failure Modes and Effects Analysis (FMEA) 9 Design for Environment (DFE) 10 Team Member Roles 11 References

Executive Summary

Daniel Tabrizi

Stakeholder Needs

Daniel Tabrizi

The main stakeholder for this product is the consumer. The consumer is the main person operating the device and is the one who will suffer the most if it fails. Cost, reliability and safety are a few of the needs the consumer has from the product. However, the consumer isn’t the only group that this product has an impact on. Retailers, manufacturers, and Shippers/transporters also have interactions with the product.

-Consumers --Cheap --reliable/maintainable --easy to use --safe --moveable between cars --compact/Light --

-Retailers --Easily displayable --high Demand --low to no maintenance required --profitable

-Manufactures --made from common materials --few parts --easily assembled --assembly can be automated to reduce cost --replaceable parts --High Demand

-Shipping/Transport --High Demand --Easily Shippable/Light Weight --Durable

Usability Study

Daniel Tabrizi

How its used The Big Red Hydraulic Bottle Jack can be operated with everything in the packaging. It does not need any additional fluid, or an electrical source. The eight-pound jack can lift vehicles weighing up to 4 tons simply by moving a handle up and down. Once the vehicle is lifted the jack can maintain the car at the required height to change a tire. To compensate for different size cars, a worm screw is attached at the top tat can extend upwards to assist in the lifting of cars that are taller.

Steps for using: 1) Retrieve pump from storage 2) Tighten screw clockwise 3) Place under car and turn cap until the piston is the desired height 4) Assemble and insert handle 5) Pump up car 6) Place jack stand and release pump by turning knob counter clockwise 7) Push jack stand all the way back in so it can be easily stored.

User Study

When the group tested the jack, without using the instruction, we found the jack very confusing. However, once we read the instructions and tried operating it, we discovered that the jack was in fact very easy to use. Although it was easy to use, there were some problems with the jack. It had trouble getting under smaller cars, which is understandable since it is designed for 4-ton cars. Also pumping the handle was challenging since the user had to kneel on the ground and lift the handle once it was lowered to pump it repeatedly. The release screw was also difficult to rotate by hand. However, with the handle bar inserted, the task became easier, but still challenging.

One of our group members gave the jack without instructions to another Carnegie Mellon student and had them jack up their car. Without help, the person also struggled initially using the jack, but ultimately decided that the jack was very compact and easy to use.

After doing research and self evaluations on the jack, the group has concluded that the item is very compact and light for a jack. The group also concluded that its size makes it very easy to store in a car and the design makes the jack very easy to use. Since there aren’t very many exposed moving parts and there is not combustion, the jack is fairly safe. Its steel design also makes it very robust and hard to damage. The only corrections the group would make is possible widening the base to prevent tipping as well as improving the handle to prevent it from getting lost. Also allowing the jack to work for a larger variety of cars cold be another improvement.

Assembly

The following is an exploded view of the hydraulic jack. The parts each number corresponds to are listed below the picture and in the Bill of Materials section.

1. Inner Handle

2. Outer Handle

3. Alligator Clip

4. Pins

5. Pump Connector Rod

6. Link Connector Screw

7. Pump Handle Housing

8. Pump Rod

9. Pump O-Ring

10. Pump Plastic Ring

11. Pump Housing

12. Pump Housing Washer

13. Valve Screw

14. Valve Screw O-Ring

15. Valve Ball Bearing

16. Base

17. Plastic Bumper

18. Plastic Fluid Filter

19. Base Plastic Washer

20. Ramrod Rubber O-Ring

21. Ramrod Plastic O-Ring Retainer

22. Ramrod Base

23. Ramrod Shell

24. Extender Screw

25. Inner Chamber

26. Outer Cylinder

27. Rubber Plug

28. Large Plastic Cap Ring

29. Outer Cylinder Screw Cap

30. English Warnings

31. Alternate Language Warnings

Daniel Mark

Bill of Materials

The following is a list of the 31 parts that make up the hydraulic bottle jack. Most pieces are made of steel, that has been shopped in some way, usually on a mill or a lathe. The non steel parts are either rubber or plastic and are purchased or injection molded. The table can be sorted by Part Number, Quantity, Weight, Material, and Manufacturing Process.

Part Number	Name	Quantity	Weight (g)	Function	Material	Manufacturing Process	Image
1	Inner Handle	1	78	Inner handle piece, used to pump fluid	Painted steel	Bent, Welded
2	Outer Handle	1	134	Outer handle piece, used to pump fluid	Painted steel	Bent, Welded
3	Alligator Clip	2	<1	Used to hold Pins (#4) in place	Aluminum	Purchased
4	Pin	2	7	Used to hold pump structure together	Steel	Purchased
5	Pump Connector Rod	2	25	Connects Pump Handle Housing (#6) to Base (#16)	Painted steel	Stamped
6	Link Connector Screw	1	5	Connects Pump Connector Rods (#5) to Pump Handle Housing (#7)	Painted steel	Riveting
7	Pump Handle Housing	1	98	Connects handle (#1&2) to Pump Rod (#8)	Painted steel	Stamped, Bent, Welded
8	Pump Rod	1	42	Moves up and down to pressurize the jack	Painted steel	Automated Lathe Process, Drilled
9	Pump O-RIng	1	<1	Creates a pressure seal for the pump	Rubber	Purchased
10	Pump Plastic Ring	1	<1	Holds the Pump O-RIng (#9) in place	Plastic	Purchased
11	Pump Housing	1	74	Limits the Pump Rod (#8) motion to 1D	Painted steel	Automated Lathe Process, Threaded
12	Pump Housing Washer	1	1	Provides separation between the base and the bottom of the Pump Housing (#11)	Steel	Purchased
13	Valve Screw	1	18	Allows for release of pressure in jack	Painted steel	Automated Lathe Process, Threaded, Stamped
14	Valve Screw O-RIng	1	<1	Creates pressure seal around the Valve Screw (#13)	Rubber	Purchased
15	Valve Ball Bearing	3	1	Creates or releases liquid seal allowing for flow between chambers	Steel	Purchased
16	Base	1	1049	Holds entire jack together, houses the various valves in the jack	Painted steel	Cast Steel, Automated Mill Process, Threaded
17	Plastic Bumper	1	<1	Holds Valve Ball Bearing (#15) in place	Plastic	Injection Molded
18	Plastic Fluid Filter	1	<1	Filters debris during liquid flow	Plastic	Injection Molded
19	Base Plastic Washer	1	<1	Seals base of Inner Chamber (#25)	Plastic	Purchased
20	Ramrod Rubber O-Ring	1	<1	Creates pressure seal around Ramrod Shell (#23)	Rubber	Purchased
21	Ramrod Plastic O-Ring Retainer	1	1	Holds Ramrod Rubber O-RIng (#20) in place	Plastic	Purchased
22	Ramrod Base	1	98	Keeps liquid out of Ramrod Shell (#23) and prevents sticking to Base (#16)	Steel	Automated Lathe Process
23	Ramrod Shell	1	310	Moves up and down lifting and lowering anything on the jack	Steel	Automated Lathe Process, Threaded
24	Extender Screw	1	176	Allows for extra heigh to be reached by the jack	Steel	Automated Lathe Process, Threaded, Riveted
25	Inner Chamber	1	314	Constrains Ramrod Shell (#23) to 1D motion	Steel	Automated Lathe Process, Threaded
26	Outer Cylinder	1	405	Houses liquid	Painted steel	Stamped, Bent, Welding
27	Rubber Plug	1	<1	Allows for initial filling of jack with hydraulic fluid	Rubber	Purchased
28	Large Plastic Cap Ring	1	<1	Prevents rubbing between Outer Cylinder Screw Cap (#29) and Outer Cylinder (#26)	Plastic	Purchased
29	Outer Cylinder Screw Cap	1	160	Caps jack and prevents pressure leak	Painted steel	Cast Steel, Automated Lathe Process, Drilled, Threaded
30	English Warnings	1	<1	Provides warnings in English	Paper	Printed
31	Alternate Language Warnings	1	<1	Provides warnings in Spanish and French	Paper	Printed

Daniel Mark

Product Functionality

Step-by-Step Instructions

Step 1.

Step 2.

Step 3.

Step 4.

To raise:

1. Turn valve screw clockwise to tighten it and create a pressure seal
2. Place jack under car and turn extender rod until it reaches the bottom of the car
3. Insert handle into pump handle housing
4. Raise and lower handle to pump up car

To lower:

1. Turn valve screw clockwise
2. Twist down extender rod
3. Pull jack out from under car

Mechanical Function

The jack is made up of a series of concentric cylinders each of which is pressurized and holds differing amounts of hydraulic fluid. When the handle is inserted into the pump mechanism and moved up and down, fluid is pumped from a reservoir in the outer cylinder into the space in the bottom of the inner chamber, pushing the ramrod shell upward. This fluid is kept inside the inner cylinder by a high-pressure valve located in the base of the jack, consisting of a check valve and a debris filter to keep unwanted solids from breaking the seal created by the ball bearing. The jack can be released by loosening the valve screw at the jack’s base, thus allowing the fluid to return to the outer cylinder until the valve screw is tightened again. This release of fluid will then lower the ramrod shell, lowering the car and allowing the jack to be removed. The ramrod also has a section that can be unscrewed, providing extra length to the mechanism.

Jack contains 3 concentric cylinders

Fluid can flow through holes located in base

Valve screw can be loosened to release fluid

Daniel Mark

Design for Manufacturing and Assembly (DFMA)

Derek Lessard

Failure Modes and Effects Analysis (FMEA)

Gloriana Redondo

Design for Environment (DFE)

Melanie Jasper

Team Member Roles

All

References

All