The document describes the design of a drywall lift mechanism intended to aid workers in safely installing drywall. Key aspects of the design include: - The frame and major components are made of durable forged steel to support the weight of drywall while lifting. - Wheels and bearings are made of grippy urethane and durable aluminum alloy respectively to aid maneuverability while lifting. - Features include extendable height, ability to rotate drywall 180 degrees, and secure mounting of standard 4' x 8' drywall sheets.

1. University at BuffaloDec 9, 2010MAE 377 Design ProjectDrywall LiftChris Sudek<br />Table of Contents TOC quot;
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Problem Identification PAGEREF _Toc279646240 3Design Analysis PAGEREF _Toc279646241 4Hand Sketches PAGEREF _Toc279646242 5Parts Design Analysis PAGEREF _Toc279646243 27Assembly Drawings PAGEREF _Toc279646244 35Full Assembly View: PAGEREF _Toc279646245 35Exploded Assembly Views PAGEREF _Toc279646246 36Select Assembly Views PAGEREF _Toc279646247 40Bill of Materials PAGEREF _Toc279646248 42Cost Analysis PAGEREF _Toc279646249 43<br />Problem Identification<br />The proposed problem was to create a lifting mechanism to aid a person in putting up drywall. Normally putting up drywall takes multiple people with a great deal of work in lifting and holding the massive panels. It is hard work and dangerous. Drywall is awkward and heavy. No one enjoys that type of stressful work so with such a design construction would become safer and more productive. With now only needing one man to do what normally would be a two or three man job also cuts down on the labor cost making each drywall job more affordable. The device needed to fit a standard 4’ by 8’ piece of drywall and aid in horizontal, vertical and diagonal mounting. This met the device needed to be versatile while still having safety in mind. The following project tackles these tasks to meet the needs of the worker.<br />Design Analysis<br />The following product was designed with the both safety and versatility in mind to help aid in an efficient and safe work environment while dealing with drywall installation. Almost every part that makes up the drywall lift is made out of durable, solid material that one would expect out of any construction device. The entire frame of the device is created out of heavy duty forged steel. Forged steel is more expensive then the commonly used cased or machined part; however, with the forging process especially with steel you gain much more strength; necessary when lifting large amounts of drywall. The entire frame is made up of forged steel and then powered coated to help reduce the chance of damage to the metal such as rust. The only part of the design that does not involve steel is the wheels, both in the physical wheels themselves and in the bearing that allow them to roll. The choice to go with urethane wheels was biased on idea that they are known for their grip and durability. The choice for using aluminum alloy for the bearings was due to the fact that aluminum alloys physical properties make it ideal for applications in bearings. Aluminum alloy bearings are known to be much more durable under a large amount of stress. Since the maneuverability is solely based on the wheels and bearings working it made sense to go with the more efficient aluminum alloy.<br />The design was just not aimed towards durability, but also versatility. As stated earlier the design includes wheels for ease of transport and slight adjustments while hanging. In addition the frame is extendible with the use of the built in crank to give the user the ability to adjust the height as needed. When it comes to getting the drywall in position to hang the plate has been designed to fit the 4’ by 8’ in both directions. The drywall can also rotate 180 degrees to take into account for any angle mounting.<br />Hand Sketches<br />Parts Design Analysis<br />Part NameImageAnalysisSupport ArmThe arm is part of the mechanism that secures the drywall in place safely while the worker is using the mechanism. There is a lip that overlaps the dry just in case the drywall gets jostled while high up in the air. The two holes on the side are used to secure the arm for either four feet or eight feet drywall. The forged steel of this part makes sure there will be no failure while in use.Support LegThe base of the mechanism is made of three of the legs to make sure there is enough support while cranking the drywall up to high levels. The legs are long to give the whole mechanism a sturdy base. The angle of the legs can also be adjusted to make sure the weight is distributed equally between the three. Like the arm this is also made of forged steel for strength.Base PlateThe base plate is where all the force from the weight of the drywall is transferred to the feet. Because of this some material was shaved to save in weight and production; however, being made of forged steel it can easily handle the stress and disperse it to the three feet.BearingDesigned with the same basic components as most bearings, the difference is the material used. With the use of aluminum bearing is quite more durable and last much longer than the standard steel bearings. Aluminum bearings perform with less friction and disputes heat much fasters putting less overall wear on the bearing.GearOne of the more important parts of the overall design. The gear has been designed into the system to lift the drywall to the necessary height once it is secured in place. Due to its forged steel nature wear will be minimal on the teeth while in use.BushingThis bushing is used in a few different locations in the design. Its most important roll is keeping the gear in line for the lift mechanism so a collapse of the lift system does not occur.Gear PinOne of the more extensive pieces specifically designed to keep the gears in place while lift as well as giving the user an extended shaft to ease in the lifting of the drywall pieces. This is most definitely made of forged steel since high torque and extensive use is guaranteed with this piece.WasherA standard ½’ washer that is used in a majority of spots in the design to allow for a tight fastener yet some movement.½’ – 13 UNC NutStandard sized nut used in the majority of the fastening in the design. Makes the need for less tools during maintenance.Inner StandOne of the two vertical components of the design that supports the weight of the drywall while in use. Strength is a must in this component so forged steel is the material of choice. This is the component that is responsible for raising the cradle.StandThe second vertical component of the design. This connects the base to the rest of the mechanism as well as houses the inner stand when the mechanism is not raised. The oblivious choice for material is forged steel due to its large role in the entire design.Support PlateThe largest component of the design. It is designed to give the most support to the drywall evenly to make sure no cracking occurs while installation.Plate BaseDesigned to connect the inner stand with the plate. There are multiple holes in the design to allow for choices in angles of the drywall when mounting. The range is 90 degrees anymore and the device can be rotated on its wheels.Plate ScrewThe one specialized screw in the entire design. The head needed to be flush with the plate so that the drywall would not get damaged while in the cradle.SliderThis is the piece that is attached to the backside of the plate that holds the two arms in place to keep the drywall in place.Pull PinA quick release pin that is used in adjusting the angle of the drywall as well as in holding the arms in place that hold the drywall.SpringThis spring is used to hold the clicker in place against the stop gear when the drywall is raised. Without it there would be no locking mechanism to keep the drywall raised.½’ – 13 UNC BoltStandard 2.5’-1/2’-13 UNC bolt used in various areas of the device for attaching with most importantly the connection between the base and the stand.Lock GearThe second gear that is meshed with the other gear to engage a locking mechanism each time the gear is raised one click. This is made out of forged steel do to the fact that the entire weight of the upper half of the device and drywall is directed to this gear when raised.ClickerThe mechanism that uses the spring to put pressure on the stop gear locking it up. The smaller whole is where the spring is connected.Wheel HolderThis part connects the wheel and bearings to one of the three legs and allows for swiveling to change direction.<br />Assembly Drawings<br />Full Assembly View:<br />Exploded Assembly Views<br />108141312119<br />7365421<br />201918171615<br />2221<br />23<br />Select Assembly Views<br />Close up of gears<br />Close Up of Rotating Mechanism<br />Bill of Materials<br />Part NumberPart NameMaterialQuantity1Wheel HolderForged Steel32WashersSteel73WheelUrethane34BearingAluminum65BushingSteel76.5 -13 UNC NutSteel1072.5’ .5 – UNC BoltSteel108StandForged Steel19Support LegForged Steel310Support ArmForged Steel211Inner StandForged Steel112Plate BaseForged Steel113SliderForged Steel214Support PlateSteel115Gear PinForged Steel116ClickerForged Steel117GearForged Steel118Lock GearForged Steel119SpringSteel120Stopper BoltSteel121Plate ScrewSteel1222Slide PinSteel323Base PlateForged Steel1<br />Cost Analysis<br />Target Retail Price: 499.99 USD<br />Costs:<br />(Consists of manufacturing, materials, labor: administrative, management, maintenance)<br />200.00 USD<br />Overhead:<br />(Consists of rent, offices, storage, shipping)<br />50.00 USD<br />Sales Commission:<br />75.00 USD<br />Wholesale Price:<br />110.00 USD<br />Retail<br />250.00 USD<br />Miscellaneous Expenses:<br />50.00 USD<br />