1. 1. Lochard, Inc. Tailgate Station Design Proposal: Prepared for: Tim Kleptz Lochard, Inc. VP of Operations Prepared by: John Walter Adam Andrews Katherine Gaiser Mauricio Nieto Erich Widmer November 7, 2014
2. 2. Transmittal OSU Senior Design Team 590 Woody Hayes Avenue Columbus, Ohio 43201 December 5, 2014 Tim Kleptz V.P. of Operations Lochard Incorporated 903 Wapakoneta Avenue Sidney, Ohio 45365 Dear Mr. Kleptz, Attached is a copy of the Tailgate Project Proposal. This proposal summarizes the design alternatives of an all-in-one tailgate station for mass manufacture to the public. Within you will find a recommendation on the best design based off of cost, functionality, and consumer convenience in order to meet the requirements presented for the ideal product design. Brief justifications are included to support the selection of this design, along with a projected timeline for the coming semester. We would like to thank Lochard for the continued support of Ohio States senior capstone program. We look forward to working with the company in the coming months ahead to benefit further from your expertise, which will enhance our professional careers as engineers in the future. If any questions regarding the contents of this proposal surface, please contact any of the team members at your convenience. Sincerely, John Walter Erich Widmer Adam Andrews Mauricio Nieto Katherine Gaiser 2
3. 3. Table of Contents Transmittal....................2 Executive Summary..........................4 Introduction...........................................4 Review of Literature.............................................5 Design Alternatives...6 Quality Function Deployment....10 Selection of Best Design......................11 Cost Analysis....12 Proposed Methods...13 Timeline....15 Conclusion and Recommendations15 References....17 Appendix A: Hand Sketched Alternatives....19 Appendix B: Specifications....24 Appendix C: Personal Qualifications........29 3
4. 4. Executive Summary Lochard, Inc. wants a tailgate station design that is easy to manufacture and will appeal to the soccer mom, as well as, the tailgate fanatic. The focus of this design will be to address the most prevalent problem with tailgate equipment today, which is a lack of options. A vehicle attached tailgate product that supplies the public with multiple features does not exist. The company saw a need for the public and they want to be the first to fill that void. In order to meet Lochards design criteria the following requirements must be achieved. Lochard wants a tailgate station that is easy to attach and detach so it can be stored when not in use. The design is to be simple, so it can easily be manufactured for mass production, as well as affordable. The client stated, I want something that will attract the masses and not the classes. Lochard indicated material for the design will either consist of aluminum, stainless steel, or a combination of both materials. Overall weight and cost to manufacture the product will drive material and hitch connection design. The tailgate station needs to be durable and within allowable weight tolerance of the vehicles hitch carrying capacity. These factors will be especially important for safety, which is important for travel and during use. Three design alternatives were produced and a final design that best meets Lochards need was determined. The first design is a suspended station directly connected to the rear of the vehicle. The second is a trailer that would attach to the vehicle from a tongue hitch trailer and ball mount connection. The third alternative is a compacted and combined design of the first two. The third design was chosen as the best because it addressed key client and design requirements such as weight capacity, storage and cost. This proposal includes an introduction, review of literature, and projected timeline with real time results. A quality function deployment (QFD) model was produced to help prioritize the most important goals for this design. Alternate design drawings with detailed explanations on their strengths and weaknesses are contained within this proposal for comparison. The best design from these alternates was determined based on customer and design requirements. Proposed methods, cost analysis, and final results will demonstrate why this design was chosen. A conclusion and any further recommendations will bring this report to a close. References of professional articles, patents, specifications and any other sources of materials used in development of this design will follow. Any relevant notes and information plus personal qualifications are included in the appendix section at the end of this report. Introduction Lochard, Inc. is a sheet metal fabrication company located in Sidney, Ohio. The company originated as Lochard Heating and Air Conditioning in 1945. In addition to HVAC services, the company has grown into a multifaceted metal fabrication company that provides services 4
5. 5. including, but not limited to, Computer Numerical Control (CNC) machining, laser/water cutting and welding/fabrication. Lochard has a small client base for fabrication and is reliant on contract manufacturing; they currently do not manufacture a product for sale directly to the public. Lochard, Inc. is seeking a unique tailgate station design that will fit most trucks and SUVs. The company developed the idea to design and manufacture an all-in-one tailgate or event entertainment station that can be used by anyone. The ideal station should offer multiple features, be easy to store, transport to and from the event, and have its own mobility while at the event. The company wants the customer to be able to move and set up the cooking station at any location while at the event without the need of a vehicle. The purpose for this proposal is to present three design options of a tailgate station for mass manufacture by the client, Lochard Inc. This proposal describes each design of the tailgate station through the use of cost and design analysis. A recommendation for the best alternative is based from the results of these analyses and is stated within this document. Review of Literature Described as the delicate balance between fandom and celebration, the origins of tailgating can be dated back to the Civil War, with the first event being the Battle of Bull Run in 1861 (American Tailgater Association, 2014). This has since come to be a multi-billion dollar industry. Twelve billion dollars is spent on tailgating activities each year (Nationwide, 2014). Two out of every five tailgaters participate 6-10 times per season and spend over $500 per season on food and supplies. With an estimated 50 million tailgaters in the United States, the design of an all-in-one tailgate station is much desired (Nationwide, 2014). Design research was conducted both to assess current tailgate products on the market and to evaluate which aspects of these current designs can be used to achieve Lochards goals. Research into the first possible design resulted in the discovery of the Moe Tailgater. Moes design consists of four storage modules that are attached to a swivel arm bar, which directly connects into the vehicles hitch receiver as shown in Figure 1 (Moeactive, 2013). Moe recommends that the containers remain empty during transport and secondly that the individual modules be removed from the swivel support system while the arm bars are rotated away from the vehicle. This warning is to eliminate any concern with whip created from the sheer weight of a loaded down hitch (Moeactive, 2013). Specifications of a class III hitch do not allow for more than a 500lb tongue weight to be applied to it (eTrailer, 2014). Each Moe module weighs between 40-70lb not to exclude the added weight of the swivel arm bar support (Moeactive, 2013). Adding any additional weight from items and the added moment and shear force during transportation, its apparent the maximum allowable weight of 500lb would be exceeded. Figure 1: Moe Tailgater attached tailgate module design 5
6. 6. Patents were researched in order to gain an understanding of how the swivel hitch could be implemented to the station. The first patent (Didlake, Ralph L., 1996) was designed to support a cargo container. This design limited the height of the container to be rotated away from the car and failed to offer any additional support once rotated. The second patent (LeDuc, Ernest W., et al, 2004) supplies a pedestal attached to a swing arm hitch support assembly. This design lacked support when rotated away from the hitch. This patent did provide a basic concept that would allow for a grill to be at a comfortable level. The third patent (Theodore, Bill R., 1959) is to be incorporated, which allows for an automatic retractable hitch leg. The hitch leg incorporates a wheel assembly which allows for easy mobility and function. Existing trailer designs were assessed to develop an organized station. Towable Tailgates and Fanatic Tailgate Trailers Inc. offer multiple features for tailgating parties as shown in Figure 2 (Creations, 2014). These competitors put forward full size trailers that raise cost and storage issues. The client expressed that the station needs to be affordable, so these trailer designs would be outside the allowable cost. As a result, only certain aspects from these designs might be incorporated into the final design. Existing tailgate kiosk stations were evaluated to discover a more compact option. Imagi-Motive LLC was considered as an option because of the small scale tailgate trailer they offer as shown in Figure 3 (Imagimotive, 2014). This was identified to be the most compact version of a tailgate station, yet the design did not allow for an awning or umbrella nor was it able to move without the assistance of a vehicle. These existing tailgate options only attract the avid tailgate fan because they were created to reach a specific demographic. Additionally these designs are too expensive for the average tailgater. Design Alternatives & Feasibility Our teams goal is to provide Lochard Inc. with three viable options for tailgating. If a hitch receiver is to support the entire unit a maximum of 500lbs is not to be exceeded, for that is the maximum weight a class III hitch can withstand (eTrailer, 2014). Additionally, if a trailer is more suitable, it should not exceed 5 feet long, 3 feet wide and 3.5 feet tall. These conditions were adapted by the team in order to satisfy storage and shipping concerns expressed by Lochard Inc. Figure 2: Towable Tailgates and Fanatic Tailgate Trailer Inc. trailer design Figure 3: Imagi-Motive LLC compact trailer design 6
7. 7. Design #1: Figure 4: Orthographic Projection of Design #1 Image 1: Rendered Exploded View of Design #1 Lochard initially wanted a tailgate station that would be suspended and supported directly from a Class III trailer hitch receiver. The design shown in Figure 4 and Image 1 addressed several of the requirements from the client. It would directly connect to the hitch and potentially swivel out 7
8. 8. as required for access into the vehicle. Additionally, the design was simple and also supplied storage capacity for cooking equipment, gear, entertainment items, and other various items. However, there were drawbacks that ultimately led to the clients decision to reject this design alternative. The main concern is with the overall weight capacity of the hitch receiver, which is a maximum allowable tongue weight of 500 lbs (eTrailer, 2014). Lochard wants the material for the station to be either aluminum or stainless steel. They also stipulated that the station needs to be able to support the added weight of any food, beverages, utensils and other items to be stored within a cooler and the station drawers. Lochard speculated that it would not be feasible to build such a station after factoring in the dead load of the station, live load of stored items, reaction force from wind resistance and moment reaction encountered during travel. Upon completing this design alternative in SolidWorks, it was apparent that Lochard was correct in their determination because the overall weight of this station exceeded 800 lb as aluminum and 2300 lbs as stainless steel. Design #2: Figure 5: Orthographic Projection of Design #2 8
9. 9. Image 2: Rendered View of Design #2 Image 2 presents the design for a trailer that would attach to a hitch receiver. This design covers many of the requirements described by Lochard listed in Table 1, such as storage space for the customer, entertainment, appearance, and the ability to customize. Design 2 was thought to solve the issues with Design 1, however there are several requirements not met in this design. The station does not have its own mobility, it also would not be easy to store during the off season, and as seen in Table 4 the station is outside the acceptable range of cost, which is a direct result of its large size as shown in Figure 5. 9
10. 10. Design #3: Figure 6: Orthographic Projection of Design #3 In order to satisfy the main requirements established by the client it was determined that a combined tailgate design that incorporated aspects of Design #1 and #2 would need to be developed. As a result, Design #3 was created in SolidWorks. This design appeals to a variety of people with its accessibility and ease of use. The compact design shown in Figure 6 addresses the clients concern with overall size and weight. Quality Functional Deployment Table 1 demonstrates the importance of the teams design options per customer requirements and design requirements. The table also compares the relevance of existing tailgate stations with the three design alternatives provided in Figure 4, 5 and 6. As depicted in the table, Design #3 (compact trailer design) clearly outweighs all other designs. Table 1 shows Design #3 to be the best with an overall score of 7.2. Comparing this score with the other two design alternatives, Design #3 outscored Design #1 and #2 by 2.0 and 2.2, respectively. These scores are calculated by assigning a weighted number system to the clients requirements and determining which criteria proved to be the most important in conjunction with design requirements by assigning a score of 1-9 within the relationship strengths section. 10
11. 11. Table 1: Quality Function Deployment Selection of Best Design Design #3 was determined to be the best overall design for the project. The main contributing factors that led to this decision are; safety, overall price, size, weight, mobility, storage capacity and ease of operation. The tailgate assembly proved to be the best choice in regards to mobility. The compact design will reduce the overall size and weight, plus increase the level of safety for both use and transport. Reduction of weight may also allow the consumer to manually move the unit without the need for a motor vehicle, or a supplemental mobile device when storing and/or positioning at site. Furthermore, the design provides space for storage of commodities, cooking equipment, and also the installation of entertainment products, like speakers. This design is the most cost effective as demonstrated in Table 2 and 3. Design #3 (Tow Behind Caddy) is the best station to provide low manufacturing cost that will potentially result in profit and also allow consumers to outfit the station without draining their bank account. Mobility, cost, features and overall weight is what sets this design apart from Design #1 and #2, and will separate it from current tailgate designs available on the market. 11
12. 12. Image 3: Rendered View of Design #3 with features; see Table 2 & 3 for overall cost of unit and optional features Cost Analysis Table 2 shows the initial cost analysis of three diverse designs. The major factors of these designs have been incorporated into the cost and broken down into their respective categories. The option to construct each tailgate station design out of aluminum or stainless steel was explored and is included in Table 2. However, the cost of aluminum and stainless steel are estimates. Further analysis will be required to explore the option of purchasing the material from wholesale markets. Lochard will be expected to provide up to date accurate costs of manufacturing the proposed design. 12
13. 13. Table 2: Cost Analysis for Manufacture of 3 Design Alternatives Image 3 shows a rendered representation of Design #3 (Tow Behind Caddy possible name) with added features. This is to demonstrate overall cost of adding these amenities, so Lochard can estimate a cost for the base unit they will manufacture and also have an idea of what the consumer will need to spend in order to utilize all available features. Table 3 provides a cost break down of these features. Specifications of these products are located in Appendix B. Table 3: Optional Equipment Cost One feature that is not shown for any design is mobility. Research into this option resulted in little existing designs that met what the client wanted. As a result, this will require design of a new product, which would not be feasible in order for design, fabrication and assembly of the station to be completed. Therefore it is recommended that Lochard offers this as an option to the customer in the form of the only product that did meet their need, which is the EZ Tug (EZ Tug, 2009). Specifications for this product are included in Appendix B as a possible option. This option is not represented in Image 3. Proposed Methods Lochard will select the best design from the three alternatives provided within this proposal. Detailed SolidWorks drawings will be created starting in December and will continue into February. Strength and flow analysis testing will also be conducted using SolidWorks 3D CAD Item Cost of Aluminum ($0.65/lb) $325.00 $1,300.00 $520.00 Cost of Stainless Steel ($0.92/lb) $736.00 $1,840.00 $736.00 Manufacturing Shipping Cost Axle Tires Battery Propane tank Stove Top Storage Hinges TOTAL COST $1,702.55 $1,291.55 $4,415.15 $3,875.15 $1,267.11 $1,051.11 $80.00 $19.99 $235.98 $80.00 $19.99 $19.99 $80.00 $16.79 $16.79 $0.00 $17.80 $26.40 $21.12 $235.98 $145.99 Tow Behind Caddy Trailer Hitch Assembly $100.00 $350.00 $80.00 $330.00$1,800.00 $250.00 $0.00 $0.00 $145.99 Optional Equipment Audio Unlimited Premium 900MHz wireless Indoor/Outdoor 205.00$ Napolean Marine Portable (PTSS165) 189.00$ Igloo Thermoelectric Cooler $99.99 Adcraft Food Warmer $118.99 13
14. 14. packages. The drawings and test results will be delivered to Lochard for review. Drawing revisions and additional testing will occur as required until the client approves the design for fabrication. Fabrication of the tailgate station will start in February. Scheduled trips to Lochards facility to assist in the fabrication of this product will be established with their representative. Any outsourced parts needed will also be ordered at the beginning of fabrication. Completion of the fabricated product is expected sometime in February and assembly should start near the end of February, or beginning of March. The Ohio State senior project team will assemble the tailgate station, once the fabricated parts are received from Lochard. Installation of any outsourced equipment or parts will also be added at the appropriate time during assembly. Testing of the station will occur when final assembly is achieved. Testing will consist of attaching the station to a class III hitch receiver and transporting it to a set location. Additional testing will be conducted after successful transport of the station and include using the station to cook food and serve to a set number of people in order to simulate a tailgate experience. Any issues or concerns during these tests will be noted and included within the final report along with recommendations. A final report will be compiled and delivered to Lochard, along with the final product, upon completion of this course. 14
15. 15. Timeline Table 4 is a Gantt chart that defines the process that will guide our team through the development of this product. This chart has served as a means to keep the group up to date, focused on main deadlines and overall details of the tailgate station. Table 4: Gantt Chart Showing Current and Projected Tasks Conclusion and Recommendations The tailgating industry continues to expand into a growing multibillion dollar industry. For this reason, it was determined by Lochard that there is a high demand for an all-in-one station that fulfills the needs of the average tailgater. 15
16. 16. Research into current marketed products by implementing QFD and cost comparison analysis have led to the selection of the Tow Behind Caddy. This design meets both the customer and design requirements and is also the best choice in regards to cost. For these reasons its recommended that Lochard accept this design and allow continued design development to occur, so that it can be fabricated, assembled and tested for possible mass production. 16
17. 17. References All about Trailer Hitches. The Trailer Hitch Experts. n.p., n.d., Web. 23 October 2014 Americantailgaterassociation.org, (2014). History of Tailgating: A Time-Honored Tradition | American Tailgater Association. [online] Available at: http://americantailgaterassociation.org/news/history-tailgating-time-honored-tradition/ [Accessed 24 Oct. 2014]. Aussiewheel.net.au, (2014). Aussiewheel Boat & Caravan Movers | Power Mover Range Aussie Wheel. [online] Available at: http://aussiewheel.net.au/products.html [Accessed 24 Oct. 2014]. Creations, P. (2014). Tailgate Trailers from Towable Tailgates - Tailgating Trailers, Tailgate Trailer - 1-877-7-TOWABLE. [online] Towabletailgates.com. Available at: http://www.towabletailgates.com/ [Accessed 24 Oct. 2014]. Didlake, Ralph L., (1996). Patent US5544799 A Swing away cargo carrier assembly. [online] Available at: http://www.google.com/patents/US5544799 [Accessed 24 Oct. 2014]. eTrailer.com, (2014). Trailer Hitch Receiver Sizes. [online] Available at: https://www.etrailer.com/faq-hitch-size.aspx [Accessed 05 Nov. 2014] eztug.com, (2009). Features.[online] Available at: http://www.eztug.com/secondlevels/features.shtml [Accessed 07 Nov. 2014] Imagimotive.com, (2014). Tailgate Trailers by Imagi-Motive | Magnolia, Texas USA | Imagimotive. [online] Available at: http://imagimotive.com/tailgatetrailer/ [Accessed 24 Oct. 2014]. LeDuc, Ernest W., et al, (2004). Patent US6701913 - Swingable apparatus attachable to a vehicle for transporting a cooking device and permitting access to the vehicle. [online] Available at: https://www.google.com/patents/US6701913?dq=us6701913&hl=en&sa=X&ei=lFtKVJXJ KcP-yQT7hIHABQ&ved=0CB8Q6AEwAA [Accessed 24 Oct. 2014]. Moeactive.com, (2014). Tailgater The MOE - Tailgating and Camping like a Pro. [online] Available at: http://www.moeactive.com/catalog/product/view/id/8/s/tailgater/category/7/ [Accessed 24 Oct. 2014]. Nationwide.com, (2014). What Is Tailgating? | Tailgating Statistics and History | Nationwide.com. [online] Available at: http://www.nationwide.com/tailgating-history- statistics.jsp [Accessed 24 Oct. 2014]. 17
18. 18. Powtrailers.com, (2014). POW! Tailgating. [online] Available at: http://powtrailers.com/# [Accessed 24 Oct. 2014]. Prohoists.com, (2014). PROHOISTS - Wheelchair Hitch Scooter Carrier and Ramp 500lb Medium. [online] Available at: http://www.prohoists.com/Wheelchair_Hitch_Scooter_Carrier_and_Ramp_500lb_Medium [Accessed 24 Oct. 2014]. Rowland, Edward R., et al, (1999). Patent US5992871 - Swing-away trailer hitch/coupler and method of manufacturing. [online] Available at: https://www.google.com/patents/US5992871?dq=us5992871&hl=en&sa=X&ei=eVtKVNH 0Doa3yATbn4GwDA&ved=0CB8Q6AEwAA [Accessed 24 Oct. 2014]. Theodore, Bill R., (1959). Patent US2882070 - Automatically retractable hitch leg. [online] Available at: https://www.google.com/patents/US2882070?dq=retractable+hitch+wheel&hl=en&sa=X& ei=C9pGVNvjJoK3yATBhIKIDg&ved=0CCsQ6AEwAg [Accessed 24 Oct. 2014]. Venture.eurekaboy.com, (2014). Stinger trailer conversion. [online] Available at: http://venture.eurekaboy.com/stingertrailer.htm [Accessed 24 Oct. 2014] 18
19. 19. Appendix A: Hand Sketched Alternatives 19
20. 20. Figure A1: Orthographic Projection of Design #1 Figure A2: Orthographic Projection of Design #2 20
21. 21. Figure A3: Projected View of Design #2 21
22. 22. Figure A4: Top and Right Side View of Design #3 22
23. 23. Figure A5: Back View of Design #3 23
24. 24. Appendix B: Specifications 24
25. 25. EZ Tug: 1. Moves trailers at a constant speed of 37 feet per minute 2. Steer forward and reverse 3. Automatic locking wheel 4. Security with removable Tiller Handle 5. Powerful 12 volt DC motor with circuit breaker overload protection 6. Smooth and quiet operation 7. Jack swivel lock when fully retracted 8. Maximum trailer weight 3,000 lbs on level surfaces.* 25
26. 26. 9. Quality made in USA EZ Tug Installation and Performance Information 1. Will install on all square tubing trailer tongues up to a maximum of 5" 2. Will also install with 2-1/2" diameter snap ring type mountings 3. Moves all trailers up to a maximum gross weight of 3,000 lbs.* 4. EZ Tug moves all trailers at a constant speed of 37 feet per minute 5. Maximum tongue weight at EZ Tug 352 lbs. with tire inflation at 50 psi 6. EZ Tug jack travel 9 7/8" with minimum height at 12" Napoleon Marine Portable Gas Grill: MSRP: $189.00 Warranty: President's Limited Lifetime Fuel Type: Propane Burners: 1.00 Total BTU's: 9,000.00 Total Cooking Area (Square Inches): 165.00 Burger Capacity (4 Inch Diameter): 10.00 Colors: Stainless Steel Admiral Craft (FW-1200W) Full-Size Countertop Food Warmer: Ship Weight 20 lbs. Amps 10 Control Type Thermostatic Dimensions (H x W x D) 9.25" x 14.5" x 22.5" Metal Type Stainless Steel Pan Size Full Power Electric Voltage 120 Wattage 1,200 W Igloo Cooler Thermoelectric: IcelessTM 28: Cools without ice more room for food and drinks Cools down 36F below surrounding temperature Quiet brushless motor and convection cooling - fan circulates cold air Ergonomic design - curved back comfortably hugs your side while carrying 26
27. 27. Swing-up bale handle with comfort grip for easy carrying Molded-in side handles for two handed carrying or lifting 8' long power cord plugs into any 12V DC receptacle (e.g. cigarette lighter) for portable use good universal fit in 12V outlets Audio Unlimited Premium 900MHz Wireless Indoor/Outdoor Speakers: General Product Type: Speaker system Height: 10.4 in Weight: 4.5 lbs Dimensions - Diameter: 5.1 in Enclosure Color: White Speaker System System Components: Transmitter, 4 speakers Speaker Type: 2-way - active Nominal Output Power (Total): 40 Watt Max (RMS) Output Power (Total): 80 Watt Audio Amplifier: Integrated Transmission Range: 150 ft Recommended Placing: Outdoor, indoor Controls: Power on/off, volume Additional Features: Auto power on/off, water resistant , weather resistant, integrated wall mount Speaker System Details 27
28. 28. Speakers Included: 4 x speaker - 2-way - 10 Watt - 40 - 12000 Hz - wireless Driver Details: Speaker : 1 x woofer driver - 3" Speaker : 1 x tweeter driver - 2" - mylar Connections Connector Type: Audio line-in ( mini-phone stereo 3.5 mm ) Miscellaneous Included Accessories: Audio cable kit, power adapter, remote control Remote Control: Remote control - infrared Power Power Device: Power adapter - external Battery Type: Battery - C type Required Qty: 6 Included Qty: 0 Manufacturer Warranty Service & Support: 1 year warranty Service & Support Details: Limited warranty - 1 year 28
29. 29. Appendix C: Personal Qualifications 29
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