Operators Manual Automatic Lift System for Danielle Giroux

By Team 5

Kayla Gosse Leah McElhaney

Jordan Smith

4/20/2012

Client Contact Information:

Dave and Suzanne Giroux

53 Charlotte Dr, Tolland, CT 06084

girouxs@sbcglobal.net

860-604-0893

1

Important Safety Instructions

Safety of the client is the number one priority for this design. The lift and ramp mechanisms

will need to be structurally sound and tested before the client will be able to use the device. Most

scissor lifts are made with stainless steel; the optimal design for this device calls for the scissor

lift to be made of aluminum. Mechanical testing and analysis will need to be completed to ensure

that an aluminum lift will maintain the structural and mechanical integrity of the lift the same

way stainless steel does.

There are several more mechanical safety issues involving the optimal design. Since the

design has a ramp incorporated into the scissor lift, several precautions will be taken to ensure

the ramp will not buckle underneath the client’s weight. The client and her wheelchair weigh

approximately 110 pounds. The automatic lift and ramp will hold approximately 600 pounds.

The four support beams located underneath the ramp will add support to the ramp. The support

beams will lie on the steps and hold the ramp up when it is in use. Additionally, the ramp will be

made of two aluminum pieces secured by a hinge system. When the ramp is in use, the hinge will

be secured across the two pieces of aluminum that comprise the ramp. This feature also adds

mechanical support to the lift system. Furthermore, there will be edging attached to the lift and

the ramp when it is in use. This will provide the client with additional security when using the

lift system. The edging will ensure that the client will remain on the ramp at all times while in

use, even if the client were to lose control of her wheelchair. Additionally, adhesive treading will

be used on the lift system. To raise the lift, the client’s parent will attach the jacks to the battery

using alligator clips. The switch on the side of the base will then be held in the “up” position

until the desired height is reached. Once the ramp is level, the client’s parent will let go of the

switch and release the alligator clips from the battery. This will be controlled by the client’s

caregiver. This safety precaution is necessary so that the client cannot operate the lift alone. This

ensures the client’s safety and the sustainability of the lift system.

Routine inspection maintenance should be performed on the lift on a monthly basis to ensure

that there are no hazards to the client. The wheels should be lubricated, as well as all pivot points

with medium weight oil or light grease. The oil level will also have to be periodically checked

and filled if needed. The recommended hydraulic oil for the optimal design is a Citgo AW32. It

is very important to keep the hydraulic oil free of dirt, rust, metal chips, water, and other

contamination. This is because most problems with hydraulic systems are caused by

contamination in the oil. The nuts and bolts that hold the system together should also be checked

regularly, and tightened if necessary.

The client should not use the device unless all the necessary safety precautions have been

utilized, including the tie-downs on the platform of the lift and raising the lift 2” prior to the

client getting on.

2

Parts and Accessories

Figure 1. Welded Base Frame

Figure 2. Modified Base Frame with Jacks

3

Figure 3. Jack Wiring.

Figure 4. Switch in Base

Figure 5. Battery Attachment

4

Figure 6. Lift with Platform Attached

Figure 7. Fold-Out Ramp Attachments

5

Figure 8. Safety Edging

Figure 9. Safety Handle and Safety Hook

6

Figure 10. Support Rods

Figure 11. Threshold Ramp

Figure 12. Caster Wheel

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Figure 13. Handle

Figure 14. Hinges

Features

The features of the automatic ramp will assist the client with getting her wheelchair in

and out of her home with minimal assistance from her family members. Additionally, this

automatic ramp will be collapsible and transportable so that Danielle and her family can bring

the ramp to other locations for use, most importantly other relatives’ homes that are not suited

for people with disabilities. Currently Danielle enters and exits her home only with the help of

family members; one family member will pick Danielle out of her wheel chair and carry her in or

out of the home, while a second family member must carry Danielle’s wheelchair in or out as

well. This puts a tremendous strain on the family because Danielle is getting older and heavier.

The wheel chair she currently uses also is getting bigger as Danielle’s needs change. The project

design of the automatic ramp will eliminate the need for Danielle’s family to physically bring her

in and out of her home.

The finished device will be a combination of a system of two motorized jacks attached to a

platform, as well as a foldable ramp that will extend onto the front steps of a home, as well as a

separate threshold ramp. The device will be placed at the bottom of the stairs the client wishes to

ascend. The motorized jacks will be controlled by one switch located within the base of the lift

system. By pressing the remote control, the client will elevate the lift to the desired height of the

stairs. Then the ramp component will be unfolded and the support rods will be put in place and

secure. After the ramp component is secure in place, the client will be released from the tie-

downs on the platform and will be free to move across the ramp onto the foyer. Once on the

foyer, the client will use the threshold ramp to gain entrance into the house.

This device works in the opposite direction as well. The client will exit the location using the

threshold ramp and move across the ramp component onto the platform. The client will then be

secured in the tie-down with help from a family member. The switch will then lower the

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motorized jacks until the client is safely on the ground, at which point the client can be released

from the tie-downs and exit the platform.

This product is unique because there is not any product like it on the market. Most ramps

available on the market are stationary and require a second party to help elevate the handicapped

individual. The ramp designed for the client will promote independence for client, as well as

make her daily life more manageable for herself as well as her family.

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Table of Contents

Important Safety Instructions……………………………………………………………...………1

Parts & Accessories………………………………………………………………………….……2

Features………………………………………………………………………………………..…..7

1.0 Introduction………………………………………………………………………………..…10

1.1 General Overview……………………………………………………………………10

1.2 Step by Step Instructions…………………………………………………………….12

2.0 Maintenance………………………………………………………………………………….16

2.1 Electrical Maintenance……………………………………………………………….16

2.2 Environmental Maintenance…………………………………………………………16

2.3 Mechanical Maintenance…………………………………………………………….17

3.0 Technical Description………………………………………………………………………..17

4.0 Trouble Shooting…………………………………………………………………………….28

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1. Introduction

1.1. The automatic lift to ascend and descend front steps will be functional and practical for

the Giroux family. There are several critical components to the automatic lift that will be

taken into careful consideration. The client requests that the lift be transportable so that it can

be used in several locations. The lift will also be able to fit into the family van. When not in

use, the lift will not exceed a width of 6” to ensure enough room for the client and her family

members inside the van without jeopardizing safety. It is necessary that the lift also have tie

downs at the base for the client’s wheelchair. The tie-downs will secure the client and her

wheelchair to the lift surface so that there is no possibility of the client slipping or sliding off

the lift. Moreover, the client’s parents requested that the lift only be functional with parental

supervision. The lift will not be accessible to the client herself, and will only be able to start

and stop with assistance from a second party. The lift will be built to suit the client’s manual

wheelchair, as opposed to the client’s electric wheelchair. The manual wheelchair is

lightweight and portable, weighing approximately 30 pounds. The client weighs

approximately 75 pounds so the ramp will be designed to withstand approximately 105

pounds. The ramp will also be designed to hold more weight to ensure that as the client

grows she can continue to use the lift.

The lift will consist of a pair of 30” motorized scissor jacks that will lift a 30”x37”x1/4”

aluminum platform, with a fold-out ramp attached to it. The lift will be automatic and

transportable. The lift capacity is 700 lbs which is suitable for the client. The lift can reach

heights from 6” to 30” which is ideal for a variety of stairs. The lift is automatically operated

using a switch on the side of the base that will simultaneously move both scissor jacks. Each

scissor jack will have its own motor, and the pair will be attached to one battery. The battery

will remain external to the system, and the jacks will be attached using alligator clips that run

from inside the base of the system through a small hole to the outside of the base. The jacks

will be wired together and controlled by one switch so they will rise and fall simultaneously.

The jacks will be housed in an aluminum base. Aluminum will be used instead of steel

because it is lighter weight for easy transport. Two swivel caster wheels will be attached to

the side of the base. This will enable to the client to tip the lift system (when it is not in use)

on its side for transportability. When the lift is not in use, the platform will rest on the base

containing the two scissor jacks, and will appear to be an aluminum box. The base is created

with angle aluminum and enclosed using sheet metal. The platform of the scissor lift will be

30”x37” and ¼” thick. The platform will be equipped with tie downs for the client’s

wheelchair for safety. To raise the lift, the client’s parents will use the switch on the side of

the base to lift the platform to the desired height. Contrarily wise, to lower the lift, the

client’s parents will press the switch downward to lower the scissor jacks.

Figure 1. depicts the two 30” motorized jacks that are wired together. The wires will

remain inside the base frame of the device, while the battery will remain external to the

system.

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Figure 1. Motorized Jack Wiring

The two motorized jacks are connected to a switch that is embedded in the frame of the

device. To lift the system up, simply connect to the battery and press the switch in the “up”

direction. Once the lift has elevated the client to the desired height, the switch can be let go.

Contrarily, to bring the client down from elevation, connect to the battery and press the

switch in the “down” direction until the system is fully collapsed. Figure 2. Depicts the

switch located within the base of the device.

Figure 2. Activation Switch for Device

Next to the activation switch is a small hole that allows the alligator clips connected to

the jacks power source to remain external from the system.

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Figure 3. Alligator Clip Attachment

The battery that is used for the system is a 12V lawnmower battery with charger. The

battery can withstand 3-4 uses of the device before it needs to be charged.

1.2. The Automatic Lift System is fairly easy to use and does not require any extensive

mechanical or electrical knowledge. To begin, the list system should be placed at the foot of

any front staircase with two to four steps. The battery should be connected to the alligator

clips, and the lift should be raised approximately 2 inches, making the height of the device 6

inches. After the system is lifted two inches, the fold-out ramp should be placed on the stairs

at an angle so the client can approach the platform of the lift. Next, use the threshold ramp to

assist the client onto the device. Figure 4. Shows the threshold ramp connected to the base of

the system, with the fold-out ramp folded onto the stairs.

Figure 4. threshold ramp

There are proper tie downs located on the platform of the automatic lift. When the client has

properly positioned herself onto the lift system, a parent or second party will assist the client

by tying down her wheelchair. The tie-downs are a necessary safety feature of the system and

will allow the client to use the lift without injuring herself or others.

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Once the client’s wheelchair is safely secured to the device, a parent or second part will

connect the alligator clips to the battery, shown in figure 3. After the battery is successfully

attached to the device, the client’s parent can then press the switch (Figure 2) in the “up”

direction until the lift has reached the desired height. Then the client’s parent can release the

switch.

Figure 5. Automatic Lift System partially Elevated

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Figure 6. Elevated Automatic Lift System

Once the lift is elevated to the desired height (Figure 6) and the fold-out ramp is level, the

client’s parent will then assist the client by releasing the client’s wheelchair from the tie-

downs so she can move freely across the fold-out ramp. However, before the client can move

across the fold-out ramp, the client’s parents must first secure the four support rods on the

edge of the fold out ramp.

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Figure 7. Support Rods

The support rods can be adjusted using the pin located on the bottom of each. To release

the support rod from the u-bracket, simply grab the support rod from the opposite end and

rotate within the u-bracket so the support rods hang upright. The length of the support bars

can be adjusted using the pin on the bottom. The client should release the pin and let the

inner component of the support rod fall onto the stair below. The pin should then be inserted

into the proper hold to allow the greatest support. Once this is completed for all four support

rods, the client can safely move across the fold-out ramp.

Once the client is safely across the fold-out ramp, the threshold ramp that was used to

mount the device initially will be utilized again on the threshold of the home. The threshold

ramp will be moved to the base of the front door, and the client will be able to get into the

home with minimal assistance.

Figure 8. Threshold Ramp

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2. Maintenance

2.1. Electrical

The electrical component of the automatic lift system is only the BAL power packs for

the 30” motorized scissor jacks. The external battery is also an electrical component. The

maintenance for these components is very simple. The wire connection should be checked

regularly, and the 10 gauge wires should be replaced annually. Additionally, the motors

should be lubricated using a good SAE 10. The motor could also attract dirt and foreign

matter to enter the motor and cause trouble with the starting switch or brushes. Overheating

may result from accumulation of dirt in the ventilation openings and wear is more rapid when

dirt accumulates inside the motor. Since this device will be used outside and susceptible to

dirt and debris, the motors should be inspected periodically to determine if a thorough

cleaning is needed.

A simple procedure for cleaning the motor is as follows: First, wipe the outside of the

motor to remove all dirt and grease. Before starting to disassemble the motor, mark the exact

position of the end shields on the motor frame with a sharp center punch or file. This will

permit reassembling the motor just as it was for true bearing alignment. Care must be used in

disassembling to insure that damage is not done to parts. Remove nuts and through bolts or

cap screws holding the end shields and remove the rotor with its end shield. If the motor has

brushes, these should be removed first to avoid breaking or damaging them when removing

the rotor. Be careful not to tear the lead wires loose from the motor windings. Compressed air

at low pressure may be used, if available, to remove dust and loose dirt from inside the

motor. A soft brush or a vacuum cleaner may also be used to clean out loose dirt. Remove

grease and oil with a safe cleaning solvent applied with a paint brush and wipe clean with a

cloth. Avoid using excessive amounts of solvent directly on the windings as the insulation

may be damaged.

The wiring of the automatic lift system should be taken care of regularly. If the device is

used too often in succession, the circuit breaker will heat up and fry. To ensure this does not

happen, it is critical that the device is only used in the upward direction once, and the

downward direction once, while giving proper time in between to cool the system down. The

client should not raise and lower the system back and forth frequently, as it will ruin the

wiring.

Additionally, the battery should be charged overnight after each use. The battery used for

the device is not deep cycle; therefore it will need to be charged often to work properly.

2.2. Environmental

This device will primarily be used outside, and since the device is composed of primarily

all aluminum, it is important that the client take the necessary environmental precautions

when maintaining the device. The lift system implemented in the optimal design is

motorized. Therefore, there is no pollution or greenhouse gas emission when the lift is in use.

This feature of the ramp protects the environment on a local and global spectrum.

The automatic lift system should be cleaned with a rag or cloth frequently to prevent any

oil or debris from contaminating the system. The system should be kept indoors in a garage-

type atmosphere, and should not be kept outside overnight.

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2.3. Mechanical

The automatic lift system is all mechanical components, and the mechanical maintenance

of the device is what will keep it in good shape for many years. Safety of the client is the number

one priority for this design. The lift and ramp mechanisms will need to be structurally sound and

tested before the client will be able to use the device. Most scissor lifts are made with stainless

steel; the optimal design for this device calls for the scissor lift to be made of aluminum.

Mechanical testing and analysis will need to be completed to ensure that an aluminum lift will

maintain the structural and mechanical integrity of the lift the same way stainless steel does.

There are several more mechanical safety issues involving the optimal design. Since the

design has a ramp incorporated into the scissor lift, several precautions will be taken to ensure

the ramp will not buckle underneath the client’s weight. The client and her wheelchair weigh

approximately 110 pounds. The automatic lift and ramp will hold approximately 600 pounds.

The four support beams located underneath the ramp will add support to the ramp. The support

beams will lie on the steps and hold the ramp up when it is in use. Additionally, the ramp will be

made of two aluminum pieces secured by a hinge system. When the ramp is in use, the hinge will

be secured across the two pieces of aluminum that comprise the ramp. This feature also adds

mechanical support to the lift system. Furthermore, there will be edging attached to the lift and

the ramp when it is in use. This will provide the client with additional security when using the

lift system. The edging will ensure that the client will remain on the ramp at all times while in

use, even if the client were to lose control of her wheelchair. Additionally, adhesive treading will

be used on the lift system. To raise the lift, the client’s parent will attach the jacks to the battery

using alligator clips. The switch on the side of the base will then be held in the “up” position

until the desired height is reached. Once the ramp is level, the client’s parent will let go of the

switch and release the alligator clips from the battery. This will be controlled by the client’s

caregiver. This safety precaution is necessary so that the client cannot operate the lift alone. This

ensures the client’s safety and the sustainability of the lift system.

Routine inspection maintenance should be performed on the lift on a monthly basis to ensure

that there are no hazards to the client. The wheels should be lubricated, as well as all pivot points

with medium weight oil or light grease. The oil level will also have to be periodically checked

and filled if needed. The recommended hydraulic oil for the optimal design is a Citgo AW32. It

is very important to keep the hydraulic oil free of dirt, rust, metal chips, water, and other

contamination. This is because most problems with hydraulic systems are caused by

contamination in the oil. The nuts and bolts that hold the system together should also be checked

regularly, and tightened if necessary.

3. Technical Description

The Automatic Lift System only has one technical component, and that is the power

packs located on the 30” motorized scissor jacks. The BAL Power Pack provides automatic

stabilizing of the system at the push of a button. It is lightweight, has a high rpm, and easily

installed. The easy installation is due to the fact that it is completely bolted on which

eliminates the need for drilling or welding. The wire will run to the switch which

incorporates a 12V breaker. This sealed motor has easy access to manual override in case of

loss of power or need of extra torque. The BAL Power Pack kit includes 2 weatherproof

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motors, 1 switch, 2 breakers and necessary brackets. The power pack is designed to quickly

lower the jack to the ground, or raise it back to the closed position.

The wiring of the power packs (Figure 1 and Figure 3) incorporate 10 gauge copper wire,

various electrical connectors, electrical tape, wire ties. To install the power packs correctly,

7/16” socket (or open end wrench), adjustable wrench or socket, wire stripper, and wire

crimpers were used (an installation video is found here:

http://www.youtube.com/watch?v=Hp3ZbuoLC_0&feature=youtu.be). Figure 9. represents

the circuit diagram for the power packs.

Figure 9. Circuit Diagrams for Power Packs

To begin the mechanical fabrication of the automatic lift system, the base frame was

measured and welded together with assistance from Serge Doyon in the machine shop.

Figure 10 shows the welded base.

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Figure 10. Welded Base Frame

Once the frame was welded, the team was able to place the motorized jacks inside.

However, the team did not take into consideration the moving portion of the motorized jacks, so

four cut-outs had to be made into the base frame to accommodate the power packs. Once that

was completed, the channel aluminum was also welded to the base frame. Channel alimunim was

chosen because the bottom is cut out, so it would be easy to attach the jacks. The jack attachment

would not be exposed because sheet aluminum would eventually cover the bottom of the lift

system.

20

Figure 11. Modified Base Frame with Jacks

Once the jacks were able to move freely in and out of the base frame, the sides and

bottom of the base were attached. Sheet aluminum was used for the base enclosure and secured

using rivets. Additionally, a 37” piece of 1½” angle aluminum was welded onto the base frame

vertically. This extra piece of angle aluminum adds necessary stability to the lift and rests in

between the two jacks length wise.

The BAL battery packs were attached to the jacks prior to being placed inside the base

frame. The power packs each came with one switch per jack; however, to make it easier for the

client, the team wired the jacks together so one switch will control both jacks simultaneously.

21

Figure 12. Jack Wiring.

The jacks are wired together to one switch; a rectangular hole was cut in the base of the

lift system to house the switch that will be used to operate the lift system. Having the switch in

the base of the system was a requirement from the client, so Danielle could not accidentally

activate the lift system herself.

Figure 13. Switch in Base

The wires for the alligator clips remain inside the base of the lift; however, the battery

remains external to the lift. For this reason, a small hole was drilled into the sheet aluminum

enclosing the base frame. The alligator clips were wired through this hole so the client can attach

them to the battery.

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Figure 14. Battery Attachment

The next step in the mechanical completion of the lift system was to attach the platform

to the two motorized jacks. This was completed using nuts and bolts obtained from the machine

shop. The jacks were equipped with the proper attachments that made this assembly very easy.

The platform is a 30”x37”x1/4” sheet of aluminum, and sits perfectly over the base of the

system.

Figure 15. Lift with Platform Attached

As you can see in Figure 14, the hinges that will be used to attach the fold-out ramp

component are also attached to the platform. The next part of the lift system assembly is the

attachment of the fold-out ramp components. One component is the same size as the platform,

30”x37”x1/4”, and the second component is 30”x11”x1/4”.

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Figure 16. Fold-Out Ramp Attachments

The last components to attach to the ramp system are the safety features. First, the

aluminum edging that will go along the edge of the longer fold-out ramp. This edging is 1 ½”

angle aluminum and attached to the system using bolts.

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Figure 17. Safety Edging

The next safety feature is the adhesive strips that will be used as treading. These will be

placed on the platform, and across both fold-out ramps of the device. Additionally, a handle was

placed on the edge of the small fold-out ramp so the client can set up the system easier, and two

aluminum hooks were welded on the edge of the system that will be tied with straps so when the

ramp is being moved, the fold-out ramp will not fly open.

Figure 18. Safety Handle and Safety Hook

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The support rods were also welded on to the underside of the fold-out ramp. U-brackets

were used as hinges, as well as for support for the support rods. Four support rods were placed

on the underside of the fold-out ramp. A metal pin is used that will penetrate the support rod and

go all the way through the u-bracket. When the support rods are in use, they will swing on the

pin until they are vertical. A second pin, located at the bottom of the support rod, will then be

adjusted so the support rod is an appropriate length to rest on the stair below the lift.

Figure 19. Support Rods

The threshold ramp that will be used along with the fold-out ramp was purchased for

$136.00. It is made of aluminum, adjustable, and rolls up for easy transport.

Figure 20. Threshold Ramp

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Straps were purchased and attached to the top and bottom of the threshold ramp for easy

transportation. The ramp rolls up and can be carried by the straps similar to how a duffle bag is

carried.

Figure 21. Rolled Up Threshold Ramp

The remaining figures in this section will show how the lift will operate when the client is

using it.

Figure 22.

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Figure 23.

Figure 24.

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Figure 25.

4. Trouble Shooting

There are several instances in which the device will malfunction; however, all trouble

shooting is extremely easy and will be executed rarely. The most common difficulty the

client will have with the device is screws and bolts coming loose. Using a adjustable wrench

or socket to tighten all the bolts and nuts regularly will ensure the automatic lift system does

not fall apart.

Moreover, the wiring of the jacks to the battery is very fragile. If a wire was to come

loose, the client will just have to replace the old wire using 10 gauge copper wire of any

length. The wire connectors may also have to be replaced, as well as the alligator clips if for

some reason they become damaged.