Click to edit Master subtitle style

Trent Smith 1st Internship

Mechanical Engineer, OSU Mentor: Ron Elliott / Adam Reiner

April – September 2013

Click to edit Master subtitle style Some smaller projects •  Yaneng & Albright

contactor improvement •  Vantage motor & gear

train performance •  Vantage 2000 cost

down •  Vantage drum support

update •  Small winch OEM

support •  Series 18 refresh •  Drill winch

16.5

17

17.5

18

18.5

19

19.5

0 2 4 6 8

Line

spe

ed (f

t/sec

)

Gear train

Performance - varying gear train

Motor 1

Motor 2

Motor 3

Motor 4

Motor 5

Motor 6

Click to edit Master subtitle style Vantage carrier test fixture Background:

•  Small winch engineers previously had no way to determine whether or not Vantage gear carriers were assembled correctly

My task: •  Design and build test fixture to determine and verify proper carrier pin staking pressure

•  Outline testing procedure to verify current staking pressure

Results:

•  Test fixtures have been made for Vantage 2000, 3000 and 4000 winches. A test procedure has been outlined which will benchmark future planetary carrier performance

Click to edit Master subtitle style Vantage carrier test fixture Design: •  Fixture emulates gear housing •  Accurate, high strength tooling •  Interchangeable design – parts can be

quickly changed to test each gear set

Test Procedure: •  Carrier strength verified through input torque •  Overall deflection measured •  Process repeated with varying staking

pressures •  Benchmark for future changes

My benefit: •  Working with TDM •  Tooling design •  Modeling & drawing •  Manufacturing engineer cooperation •  Work w/ corporate purchasing for wave

springs

Click to edit Master subtitle style Vantage housing failure

Background:

•  Vantage 2000 housings were cracking in the field from plow stalling

•  Vantage 4000 housings were cracking during new supplier validation testing

My task: •  Root cause determination •  Solution brainstorming •  Stall testing •  Strength analysis •  Solution implementation

Results:

•  Both Vantage 2000 and 3/4000 housing issues have been resolved and implemented

Click to edit Master subtitle style Vantage housing failure

Exploration:

V2000 •  Loctite 410 to secure fixed ring gear •  Housing tab radius stress concentration & analysis •  Glass fiber content •  Over-performance

V4000 •  Supplier change •  Over-performance •  Pelletized colorant

My benefit:

•  Hands on winch experience •  Supplier communication •  Finite element analysis (FEA) •  Engineering drawings •  Communication and problem solving

Click to edit Master subtitle style Universal Plow Mount

Background:

•  Plow mounts are vehicle specific •  Large inventory for dealers •  Confusing purchasing process for

customers

My task: •  Lead the design and development

of a Universal Plow Mount that fits a majority of ATV’s

•  Tight timeline of design and release in under 6 months

Results:

•  Pilot run date of September 20th, 2013

Click to edit Master subtitle style

Design process: •  Brainstorming & competitive

benchmarking •  Concept selection and modeling •  Strength analysis and FEA •  Prototype build and testing •  Improvements and iterations

Experience gained:

•  DFMEA – design requirements •  DVP&R – testing outline •  Vehicle fit-ups and dealer visits •  Design of testing tools •  Cost down efforts •  Strength testing •  Company wide interaction –

finance, corp. purchasing, fab, mfg, quality, marketing, distribution

•  Dealership interaction

Universal Plow Mount

Click to edit Master subtitle style Universal Plow Mount

Additional work:

•  Drawing dimensioning, tolerancing and reviews

•  Make vs. buy •  Installation instructions •  Box selection & artwork •  Customer reviews •  BOM creation •  Tolerance stack analysis •  ECN promotion •  Hardware kit

Final product

•  Fits on most popular utility ATV’s •  Fully adjustable design – highly

likely to fit on future models without need to re-design

•  Easy to install and durable

Click to edit Master subtitle style Summary of Benefits & Experience •  Analysis Experience

–  Pull testing –  Stack analysis –  Finite element analysis –  Motor torque and speed –  Gear train performance

•  Experience with NX Modeling and Drawing –  Good understanding of drafting standards –  NX Sheet Metal & Modeling

•  Communication Experience –  E-mails –  Meetings –  Drawing Reviews –  ECN Reviews –  Supplier interaction

•  Experience coordinating with other departments –  Marketing –  Small winch –  TDM –  Manufacturing/Fabrication –  Test lab –  Corporate purchasing –  Product marketing & management –  Quality

•  Sheet Metal Experience –  Capabilities of press brake –  Sheet metal tolerances –  Selection of punch hole sizes –  Capabilities of Laser and sheet layout –  Capabilities of robotic welder

•  Documentation –  Bill of Materials for finished goods

and sub assemblies –  Installation instructions –  DFMEA, DVP&R –  FEA report –  Test report

•  Fabrication & manufacturing –  Material treatment –  Lean manufacturing –  Broaching –  Assembly line/collaboration