At the end-of-the-day: We delivered a project that met our goals & objectives, was fun to work on and will have great utility for years to come.  By having to work with space constrictions we found that simplicity can drive breakthroughs in efficiency much like the old adage: "less is more" 

CAD rendering of crane on overhead rail sytem

Actual photo of crane on overhead rail sytem

Installation of crane onto overhead rail system

The engineering of: the crane, rail system and sled were taken from the structural principles of a Howe Truss, and modern roller coaster design.  This gives the project strength and ease of movement which was on of the other leading requirements that needed to be solved.

Since one of the main goals was to maximize shop floor space: we moved many of the items that would typically be on a shop floor to the overhead rail system to that we could "kill two birds with one stone"  This gave us the opportunity to get more efficiency out of the items moved to the overhead rail system by putting tool rigs over the work being performed. We also picked up more valuable shop floor space along the way.  Once we got the overhead rail system built in the CAD sytem and into the overall shop floor plan, we realized that the equipment and shelving units that were lined up along the walls of the shop cut into the purposed travel of the  crane running along the overhead rail system.  Therefore we had two choices.  (One), we could reduce the width of the crain or , (Two): we could reduce the hight of the sheving units to allow the crain to pass overhead.  We decided to reduce the width of the crain travel which actually worked out better than expected and was the opposite of what was expected, but is a great example of how 

Then we: Did a some research to see what other people had done with the same goals and objectives?  We found that there were overhead cranes and systems that were designed to work on overhead rail systems but they typically ran on "I" beams and were not intended to have other tooling rigs and lighting apparatuses running on the same rails.

After some research and understanding of what others had done we: 
​took the the list of "Goals & Objectives: and started sketching out rough thoughts on a pieces of paper to get a sense of where we were going. Then we put the space that this was going in into a CAD System so that we could see through simulation how this particular crane was to be used.  

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CAD rendering of hoist on sled

Photo of actual hoist on sled

Installation of crane onto overhead rail system

CAD Drawing of final revision to crane & hoist

our goals:

We began by defining: A list of requirements and trying to understand how this particular crane was to be used.  The main goal was to maximize shop floor space.  We went through several conceptual 3D CAD models before we landed on the final product; mainly because we realized that the effective travel width of the crane was most efficient when it was smaller not bigger?  This was the opposite of what was expected, but is a great example of how persistence in engineering and requirements analysis work well together with 3D CAD systems to work out these issues.

why ?: BECAUSE YOUR LIFE MAY DEPEND ON IT.

Here is how WE...

​Made an Overhead Material Handling Crane where reliability & engineering are critical... 

Surprised?:  Ironically, whether you are creating Manufacturing Rigs & Apparatus for factories in China or India; or you need to make something foolproof for kids to work on, the engineering principles are the same.  In fact, if it works for kids, then chances are your odds of it working for adults will probably increase dramatically?  Like many factories & manufacturers, budgets in schools are tight and sometimes non existent. Without spending a lot of money we accomplished our goals and made a lot of kids really happy!

who was this project created for?: very happy 4th graders!

Step 3B: Complete Painting.  The Artist is able to rotate thier work and hold it into a stable postion as they are working.  Paper when wet with paint will stick to any surface that it comes in contact with.  The box that we created prevents that from happening.  The Artist is also able to raise and lower the box and work area (as shown above) so that they can work on a round surface area easily.

Step 3b: 

Step 3A: Begin Painting.  At this stage the artist is ready to begin painting the Paper Lantern. As the Artist completes a section of work they are able to rotate the Lantern as needed 360 degrees without the Lantern touching any work service.

Step 2: Place Paper Lantern on "support rig" and insert Locking Rotation pin "IN".  We placed the Paper Lantern "support wire" onto the Paper Lantern "support rig" and erected the Paper Lantern as shown (pt 7.).  We then placed the Locking Rotation pin "IN" in place to prevent the "support rig" form rotating freely while the Artist is painting the Paper Lantern (pt 8.).

Step 3: Check Paper Lantern Assembly:  Once the Paper Lantern is stretched/erected over "support wire (pt 4.) and "support rig" we checked to make sure that the Paper Lantern was secure and attached properly before painting!

Step 1: Cut Proper Shape.  We cut the above shape out to act as a rotisserie for the Lantern after being mounted on the "Support Rig" (pt 3.)  The sides were scooped out as (shown above) not to obstruct hand clearance for painting. The box has 3 levels of height adjustment, flat, 30 degrees & 45 degrees

AFTER

BEFORE

Step 2b: 

Step 3A: 

Step 2a: 

Step 1: 

Supplies Needed: simple & easy-to-find

1. Sanding block, Bamboo skewers,  

Popsicle sticks, Utility knife, Exacto knife, Straight edge razor blades & Hot glue gun  2.  Apple box, Acrylic paints, Assorted acrylic paint brushes & Painting sponge

3. Paper Lantern "support rig": Made from popsicle sticks, bamboo skewers, a 4" round piece of black foam core with 8 equally space rotation lock holes  4.  Paper Lantern "support wire" 5.Paper Lantern (laid flat)6.  Locking Rotation pin "IN": 

​Made from, bamboo skewers, a black 1/4" foam core

This is how you:

proudly make it here... in the usa!

Click Here to find out?.

As you know,when you manufacture in third world countries, you do not always have the supplies and resources readily available as you often do here in the united states.  Therefore, you need to use what you have and realize that sometimes, the simplest solutions are often the best .  More often than not, they are also the most economical.  Over the past 25 years we have learned some valuable lessons in setting up and working in factories all over the world through practical experience and occasionally, yes, even some pain.

Here is how WE... STEP-BY-STEP: APPROACHED MAKING "n" number of paper lanterns, consistently for...  as little as possible.

Scroll down to find out?.

Engineering Problems

How do you: Make an Overhead Material Handling Crane where reliability & engineering are critical...
​Because your life may depend on it?

Scroll down to find out?.

2 Different 

How do you: Make "N" number of paper lanterns consistently for... 
As little as possible?

Here is an example of how we see it?...

$money doesn't solve problems.  People and their actions do

Carrots grow from carrot seeds

it's notabout how much  $money  you spend

Its about finding  the  right  solution for your  project

about: how we work? ...