2.
Table of Contents
Cover Page 1
Table of Contents 2
Executive Summary 3
Introduction
Problem Statement………………………………………………………………….4
Client Overview…………………………………………………………………….4
Existing Solutions…………………………………………………………………..5
Key Design Specifications………………………………………………………….6
Preliminary Design Process
Brainstorming
Chairs……………………………………………………………………….7
Table Tops…………………………………………………………....……..8
Table Legs…………………………………………………………………..9
Final Design
Chairs Solution……………………………………………………….……..11
Table Tops Solution………………………………………………………...12
Table Legs Solution………………………………………………….……..12
Fabrication Process 13
Testing………………………………………………………………………………14
Conclusion 14
Future Work………………………………………………………………………....15
References 16
Appendix 17
2
3.
Executive Summary
The Verona Public Library stores tables and chairs used for library events in a closet. The
Library has asked us to maximize the relevant storage space as the current use of their storage
space is inefficient the chairs stack awkwardly and the carts that hold the tables take up too
much space.We confronted his task by both modifying the existing storage carts to store more
items, creating two original carts to store and transport table tops and putting money aside to
purchase an additional chair cart for the library.
Our team decided to use the cart designed to hold a portion of table tops and the
corresponding table legs used to only store and transport table legs we constructed carts to
only hold the legs while making a new structure specifically for the table tops. Furthermore, the
cart was modified by welding on bars to support additional table legs.
While conducting the initial site visit, we noticed a small nook in the storage closet that
was the right size to fit all of the table tops. To best utilize this space, we designed the two carts
that carry the table tops to be small enough to fit in this space. We added wheels for mobility.
Next we brainstormed solutions to improve both the efficiency and safety of the chair
storage. Since the chairs are slightly arched, stacking more than 1517 chairs results in the pile
leaning at a dangerous angle with the threat of toppling over. The library initially stored 24
chairs on each cart and approximately 20 chairs were in use at any given time. An additional cart
will reduce this number to relatively 1517 chairs.
For our budget, we were allocated $300 with the idea that the library would
contribute 100 dollars if needed. The new table top carts required the most capital to construct.
In total, about $236 went towards purchasing building materials. We were able to keep this
3
4.
number within our budget by recycling available resources. For instance, we welded scrap metal
to create our table leg solution.
As a team we ultimately reduced the space taken up by approximately ⅔. We did this by
creating two table top carts that would fit within a small nook and neatly dividing the remaining
space to store the table legs and and chairs.
Introduction
Problem Statement
The Verona Public Library stores tables and chairs used for library events in a closet. The
Library has asked us to maximize the relevant storage space because currently, the way they
store their resources is spatially inefficient the chairs stack awkwardly and the carts that hold
the tables use too much space.
Client Overview
The Verona public library opens its doors to the community, often housing outside events
in its designated community space. In order to have a space conducive to hosting multiple events
ranging in size, the library must be able to quickly and efficiently set up and remove tables and
chairs. Currently the Library stores chairs, tables, and table legs in the closet – there are carts
designated to hold the table tops and table legs, and carts to hold stacked chairs. With the present
organization, library staff must remove all the chairs and tables in order to fit into the tightly
packed closet. Making matters worse, the tables and chairs share space with an immovable data
rack and there is an entryway into an attic that must remain accessible within the closet.
Equally important, this storage situation is extremely unsafe. For instance, the chair carts
are stacked beyond capacity, causing the chairs to arch in a dangerous fashion – they are liable to
4
5.
crash on anyone who uses the chair carts irresponsibly. In addition, the data rack controls the
internet for half of the library, and it can be hazardous to have these electrical wires in a cluttered
closet.
Brian from the Verona Public library contacted the University of WisconsinMadison’s
College of Engineering to ask for help maximizing their storage capability.
Existing Solutions
An existing solution is to store both the chairs and table tops into a single, compact and
mobile unit as shown in Figure 1. Although the solution pictured here solves the storage and
organization dilemma, the chairs the library uses are not foldable and thus will not work with this
unit.
Figure 1. Combined Chair/Table Storage Solution. This is an existing solution to
storing a large quantity of chairs and tables in a space conscious manner. The structure is also
mobile, meaning it allows users to transport the chairs and tables easily [1].
5
6.
Key Design Specifications
In order to best meet our client’s needs, we focused on optimizing the storage space
similarly to what is depicted in Figure 1. There is a total of 125 chair and, on average, about 75
of the chairs remain in the closet at a time leaving 50 out on the floor in the community space.
There are a total of 25 tables and, with two sets of removable chair legs per table, a total of 50
chair legs. Since there are times when the library needs to be able to store all 25 tables and 125
chairs within the closet, we ultimately decided to split the project into three main focus areas:
chair storage, table leg storage and table top storage. These categories allowed us to better break
the problem into manageable options that we could realistically solve.
In regards to the chair storage, the client has expressed that they like the current carts the
chairs are own; however, they have safety concerns about the leaning chairs. We took this
information and used it to brainstorm ideas to keep the carts, as they function well, and modify
them to improve their safety. Below is an image of how the library currently stores chairs.
Figure 2. Existing Chair Holder.
This is how the library currently holds chairs. [2.
6
7.
The tabletops are our client’s primary concern as they are bulky, heavy and a nuisance for
the librarians to move. Currently, the library uses the cart in Figure 2 to store the table tops. The
library currently owns two of these carts, and they both take up large amounts of space while
only holding a max of 8 table tops each.
Compared to the table tops and the chairs, the table legs are not as high up on the client’s
priority list as they are small and quite portable; however, they will still contribute to the clutter
problem if not properly stored in an orderly and set fashion.
Our client has given us permission to modify the current apparatuses in order to
maximize their storage efficiency.
Preliminary Designs
Brainstorming Process
Brainstorming is a crucial part of design as it is the foundation of the entire process. We
began our brainstorming by first creating categories to keep our ideas focused and organized.
These categories included areas such as functionality, safety, cost, time, functionality and
buildability. We applied these six categories to the chair, table legs and the table tops to ensure
that we created solid designs to lead us to a functioning and reliable final product.
Chairs
Our team determined that we needed a safer and more efficient solution to store the chairs.
1. We had the idea of creating a decorative storage unit that would disguise the chairs
within a desk. Essentially, the storage unit would have two tiers and a side panel that
opens on either side. You would be able to open the side panel and store chairs sideways
on both tiers the panel would be curved, like a semicircle, to account for the curvature
7
8.
of the chairs. This unit would be made of wood so that it could function as a desk and
match the other wooden desks within the building.
Figure 3. Chair Storage Brainstorming. This image displays proposed permanent chair
storage solution. [2]
2. Another brainstormed solution included stacking the chairs in the reverse direction to
prevent the extreme curvature and the need for a new storage system.
3. Our last main brainstormed idea was to simply purchase an additional chair cart. This
would allow us to minimize the amount of chairs on each cart and reduce the threat of the
leaning chairs.
Tabletops
As our client’s primary concern, we focused on brainstorming ideas that would allow us
to easily transport and store the table tops.
1. Initially we decided to keep the existing table top carts and purchase two
additional units.
2. Our second idea consisted of us constructing our own table top carrying cart. The
cart would be extremely small and compact in its frame as it would store the table
8
9.
tops vertically to save space. In terms of materials, our team proposed it be made
out of an aluminum or steel frame with a strong wooden base. This design is
depicted in Figure 4.
Figure 4. Wooden Base Table Top Storage Unit. This image displays an idea we brainstormed
that to carry the table tops. With this option we would build two identical carts to carry 10 table
tops each. Usually, at least 5 table carts are in use by the Library and Public.
Table Legs
For the table legs, we had a few competing ideas in the brainstorming process. One regarding
with a more emphasize to the cost and time categories and the second one with a more
emphasize to the space efficiency.
1. One idea involved taking one of the cart previously used by the library to carry
the table tops and legs and welding an additional bars on the structure. (This idea
would be coupled with making a separate structure for the table tops so that we
can adequately store the table legs on a single cart and use the other cart for the
remaining 5 table tops if they needed to be stored). By eliminating the function of
holding the table tops and only storing legs, this idea doubles the capacity for one
structure to hold legs. Fig 5 shows how we plan to modify an existing table top
cart.
9
10.
Figure 5. Table Leg Storage Brainstorming 1. This image displays brainstormed options for
the table leg storage. We will modify the current cart (left) by welding on additional bars to
double the capacity (right). [2]
2. The second idea involved creating another structure that would also have the sole purpose
of holding legs. This structure would include a rectangular base with a system of bars.
There would be two levels of bars that would allow us to store the legs vertically.
Furthermore, the bars would be staggered so the top bar for the second set of legs would
be lower than the top bar for the first of table legs. This structure would be made out of
either aluminum or steel as they are both durable materials and easy to work with.
Figure 6. Table Leg Storage Brainstorming 2. This image shows the second brainstorming
option of constructing an entirely new cart with the sole purpose of holding chair legs. [2]
10
11.
Final Design
Chairs Solution
We decided purchasing a new chair cart would be the best option due to both cost and
time restraints. Building the decorative storage unit would require approximately 15 boards of
8/4 in Cedar Spanish wood at $10.99. The total purchase price would come out to $164.85
(including tax and additional fees From researching chair cart prices on amazon.com we ).3
determined that purchasing an additional chair cart cost about the same same as constructing the
decorative storage. Moreover, the chairs are not our client’s primary concern, and thus the
majority of our time is weighted towards the tabletops. Purchasing an additional chair cart saves
us both time and money. Our decision is best summarized in the following decision matrix.
Chair Solution Decision Matrix
Importance
Factor
25% 25% 25% 25% 100%
Option Cost Time Safety Functionality Score
1.Decorative
storage unit
5 1 5 2 3.25
2.Reverse
stacking order
5 5 0 0 2.5
3.Purchase
additional cart
3 5 5 5 4.5
Table 1. Chair Solution Decision Matrix. This decision matrix proved option 3 to be the best. [2]
11
12.
Table Tops Solution
We decided to construct a new unit as it would best minimize the space needed to store
the table tops. This decision is best summarized in the following decision matrix.
Table Tops Decision Matrix
Importance
Factor
20% 20% 20% 20% 20% 100%
Option Cost Time Safety Functionality Buildability Score
1.Purchase
additional Unit
1 5 4 1 5 3.2
2.Construct
Specialized Unit
4 3 4 5 5 4.2
Table 2. Table Tops Decision Matrix. This decision matrix proved option 2 to be the best. [2]
After considering the safety and functionality, we decided to build the cart out of steel
with a base made of wood. With steel it would weigh down the design to prevent people from
pulling the design and causing it to tip over. Also from discussing welding materials with the
CoE shop managers, we found that it is easier to weld the frame with steel compared than
aluminum.
Table Legs Solution
We determined the final design by doing both a cost analysis to find the cheapest and
most efficient option and a decision matrix. We chose option 1 as building this only required us
to weld on two additional bars we found these in a scrap pile, so they were essentially free.
This option only required us to purchase bar caps for safety at $2.38. Option 2 consists of
building a new unit. The construction of a new unit would require us to purchase additional
metal. This decision is best summarized in the following decision matrix.
12
13.
Table Legs Decision Matrix
Importance
Factor
25% 25% 25% 25% 100%
Option Cost Time Safety Functionality Score
1.Modify
existing unit
5 3 5 5 4.5
2.Purchase
additional unit
1 5 5 3 3.25
Table 3. Table Legs Decision Matrix. This decision matrix proved option 1 to be the best. [2]
Fabrication Process
The group started by wiping off all the metal with acetone to clean off oxidation and
impurities. Once the metal was cleaned we sorted them out. Four 48 in steel angles were marked
at 20 ¾ in and 24 ½ in and cut with the drop saw. Four of the 72 in steel angle were marked at
3ft and cut. Two of the 72 in steel flat bars were marked at 3 ft and cut. Four of the 48 in steel
flat bars were marked and cut into four 20 ¾ in pieces and four 24 ½ in pieces. The pipe for our
table leg cart was marked and cut at an appropriate size. The sheet of plywood that was 2ft x 4ft
long was marked at the 2 feet and cut with the table saw.
Once the steel angles and steel flat bars were cut, we started to weld the base of our table
top cart. We connected the four steel angles at a 90degree angle and repeated this for our second
base. The four 3 ft steel bars for the first cart were held straight up by one member while the
other person welded it to the base; this was repeated three more times. After the four steel bars
were welded, two 24 ½ in steel flat bars were welded on opposite sides on top and one 20 ¾ in
13
14.
flat bar was welded to the other side, leaving one side open for the table tops to be inserted. We
noticed that our cart was not straight like we wanted therefore we had to grind a slit on the
bottom and top, readjust the side, and reweld at the top and bottom where it was cut. The cart
was then flipped over and four wheels were welded to the frame of the cart, each placed on one
corner.
Once we started the second cart we had to figure out a way to keep our steel bars straight.
Instead of having a person holding it up straight, we clamped the steel angles to temporary
supporting bars, ensuring they would be straight. Because of this process, the second cart turned
out much better than the first and no alterations were necessary.
Each cart was given three to four coats of metallic colored spray paint. Pieces of rug were
also cut to fit the bottom and around the tops of the cart to prevent nicking from the table tops.
An image of the finalized table top cart can be found in Appendix C.
Testing
The goal of this project was to maximize the closet storage space. In order to ensure that
we meet this goal, we conducted virtual testing by designing a layout of the closet and testing to
see if the carts we have built will store all of the necessary items and fit compactly in the allotted
space. The library has a total of 25 table tops and at least 5 usually remain in use. The two table
tops we constructed are 2x2 feet and each table top measures 2 inches thick thus the carts can
hold a total of 10 table tops each. Appendix A is a visual depiction of how we plan to arrange the
closet so that the carts fit comfortably.
Conclusion
14
15.
Our client, the Verona Public Library, needed to maximize their closet storage space. Our
client, the Verona Public Library, needed to maximize their closet storage space. Our tasks was
to give them a product that fits all their specifications and needs, while remaining within the
budget of $300. We brainstormed numerous ideas in regards to storing the chairs, table tops and
table legs. In the end, we voted on the designs that were more efficient to make and that allowed
us to remain within our budget.
In terms of the budget, we were allocated $300 with the idea that the library would
contribute an extra 100 dollars if needed. In total, $250 went towards purchasing building
materials. We were able to keep this number within our budget by recycling resources. For
instance, we welded scrap metal to create our table leg solution.
Our final budget is listed under Appendix B.
Future Work
Many of our project decisions were based on the constraints. For example, our initial
$300 with the $100 that the library gave us. For any engineering project design there are always
aspects that could be improved. The chairs were left alone since that was the best option. If there
was not a limit, the best option would have been to buy an entire set of chairs.
15
17.
Appendix A. Organization of closet
A1. Proposed organization of the closet. This image outlines not only the dimensions of the
closet we sought to organize, but it also shows how we plan to place each specific item in an
orientation that allows mobility within the closet and access to the utility stairs. [2]
17
18.
Appendix B. Final Budget
Plywood
1/2 in thick x 2 ft wide x 4 ft
long $12.05 1 $12.05
Steel angle 1 in x 48 in x 1/8 in thick $7.89 4 $31.56
Steel angle 1 in x 72 in x 1/8 in thick $12.97 4 $51.88
Steel flat bar 1 in x 72 in x 1/8 in thick $9.72 2 $19.44
Steel flat bar 1 in x 48 in x 1/8 in thick $6.80 4 $27.20
Spray paint
11 oz. Black Night Protective
Enamel Metallic $5.77 2 $11.54
Wheels
145lb wt limit : 5'' diameter :
513/16'' mount height' $11.97 8 $95.76
Rubber pipe
caps
1 in diameter, white (pack of
4) $2.38 1 $2.38
Total(2 table
racks) $251.81
B1. This table documents the items we purchased and their costs. [2]
18
