Hydraulic Front-end Bucket Loader For A Personal Lawn
Hydraulic Front-End Bucket Loader for aPersonal Lawn TractorA thesis submitted to theFaculty of the Mechanical Engineering Technology Programof the University of Cincinnatiin partial fulfillment of therequirements for the degree ofBachelor of Sciencein Mechanical Engineering Technologyat the College of Engineering & Applied Scienceby:ADAM C. DEHNEBachelor of Science University of CincinnatiMay 2012Faculty Advisor: Laura Caldwell
ACKNOWLEDGEMENTSI would like to take this opportunity to say Thank You to all of the people that inspired me tonot only complete this project but, also to the people that has inspired me to be a betterperson, student, husband, brother, son and friend.A thank you to my Wife, Andrea Dehne, who helped me to see that education, in general,and continued education, is extremely beneficial. Also, for supporting me throughout mydegree and this project.A very special thanks to the companies and individuals that provided sponsorships andmonetary donations. Also, to the individuals who donated their time and to the folks who lenta hand during the process. The completion of this project may not have been the samewithout your contribution. Thank you!Thank you to the individuals/companies listed below (listed in no particular order):Andrea DehneTeresa DehneJohn DehneCincinnati Hose & FittingShirley CarrollCurtiss MyersHydraForceDoug RifeLaura CaldwellMaster PneumaticAtlas DowelDavid ConradFirestoneISCARAnd to everyone who lent a hand!Thank you very much,Adam C. Dehneii
TABLE OF CONTENTSACKNOWLEDGEMENTS . IITABLE OF CONTENTS . IIILIST OF FIGURES .VLIST OF TABLES . VIABSTRACT . VIIPROBLEM DEFINITION AND RESEARCH . 1PROBLEM DEFINITION AND BACKGROUND . 1RESEARCH-INTERVIEWS . 2ONLINE RESEARCH - TECHNOLOGY AND EXISTING PRODUCTS . 2FRONT-END BUCKET LOADER RESEARCH: . 3RESEARCH SUMMARY:. 7CUSTOMER NEEDS TO ENGINEERED FEATURES . 8CUSTOMER NEEDS/FEATURES . 8SURVEY FEATURES WITH AVERAGES: . 9PRODUCT/PROTOTYPE FEATURES WITH MODIFIED IMPORTANCE . 10PRODUCT OBJECTIVES . 11PRODUCT OBJECTIVES SUMMARY . 13PRODUCT/ENGINEERING CHARACTERISTICS WITH RELATIVE IMPORTANCE . 14DESIGN . 15DESIGN ALTERNATIVE . 15LOAD CAPACITY AND TIP OVER . 16MECHANICAL SYSTEM OVERVIEW AND SOLID MODEL . 17BUCKET . 18BUCKET ANALYSIS . 19ACCESSORY MOUNT . 20ACCESSORY MOUNT ANALYSIS . 21LOADER ARMS . 22RISERS . 23LOADER ARMS SUPPORTS . 24LOADER ARM ASSEMBLY ANALYSIS . 25MECHANICAL SYSTEMS PINS AND BUSHINGS . 26HYDRAULIC SYSTEM OVERVIEW . 27PUMP . 27TWO GROOVE V-BELT PULLEY . 28SINGLE GROOVE V-BELT PULLEY . 29CUSTOM IN-LINE BELT AND TENSIONER . 30HYDRAULIC CYLINDERS . 31HYDRAULIC CONTROLLER . 32FLOW DIVIDER . 33HYDRAULIC HOSE AND FITTINGS . 34FABRICATION AND ASSEMBLY . 352-GROOVE V-BELT PULLEY . 35LOADER BUCKET . 37TESTING AND PROOF OF DESIGN. 38iii
ROLLING FEATURE TESTING . 38FULL LOAD TESTING . 39PROJECT MANAGEMENT . 40SCHEDULE: . 40SCHEDULE CONT. . 41PROJECT SCHEDULE SUMMARY. 41BUDGET: PROPOSED . 42BUDGET: ACTUAL . 43CONCLUSION . 44RECOMMENDATIONS . 44REFERENCES: . 45APPENDIX A – LOADER/PLOW REASEARCH . 1MODEL 50 ASABE INFORMATION . 4APPENDIX B – SURVEY WITH RESULTS . 1APPENDIX C – QFD RESULTS . 1APPENDIX D - PRODUCT OBJECTIVES . 1APPENDIX E – SCHEDULE . 1PROPOSED SCHEDULE . 1ACTUAL SCHEDULE . 2APPENDIX F – DIMENSIONAL DRAWINGS . 1LOADER ARM SUPPORTS ( LAS): . 1RISER: . 6LOADER ARMS: . 9CROSS BEAM: . 10ACCESSORY MOUNT:. 12BUCKET: . 13PIN BUSHINGS: . 25HYDRAULIC PUMP MOUNT: . 27HYDRAULIC PUMP - BELT TENSIONER:. 31HYDRAULIC CONTROL MOUNT: . 34HYDRAULIC CYLINDER(S). 35TWO GROOVE PULLEY . 36DIFFERENTIAL FAN SPACER . 37GAUGE CLUSTER . 38FILTER BRACE/BRACKETS . 39RESERVOIR BRACE/BRACKET . 41KICK STAND . 42FLOW DIVIDER . 43APPENDIX G – BUDGET . 1iv
LIST OF FIGURESFigure 1: Johnny Bucket Jr. (2). 3Figure 2: Husqvarna Front Scoop (3) . 4Figure 3: Koyker Loader Model 50 (4). 5Figure 4: Craftsman 14” Snow Blade (5) . 6Figure 5: Johnny Snow Plow (6) . 7Figure 6: Surveyed Customer Features . 9Figure 7: Features sorted by Relative Weight. 10Figure 8: Top Product Objective. 11Figure 9: Relative Importance of Engineering Characteristics . 14Figure 10: Straight vs. Mitered Loader Arm Configuration . 15Figure 11: Systems Center of Gravity Points of Intrest . 16Figure 12: Two position Side View of loader system. 17Figure 13: Front Isometric View of Loader System . 17Figure 14: Back Isometric view of the systems Bucket . 18Figure 15:FEA of Bucket . 19Figure 16: Back Isometric view of the Systems Accessory Mount . 20Figure 17: Accessory Mount FEA . 21Figure 18: System Dead-Lift Point FEA . 21Figure 19: Cross Beam and Loader Arms. 22Figure 20: Front Isometric view of a single Riser . 23Figure 21: Back Isometric view of an individual LAS . 24Figure 22: FEA of Loader Arm Assembly . 25Figure 23: FEA of Riser with Factor of Safety Concern . 25Figure 24: Riser with Machined Bushings. 26Figure 25: Hydraulic Pump . 27Figure 26: Fabricated Two Groove Pulley. 28Figure 27: Pump Pulley . 29Figure 28: V-Belt Dimensions and Image . 30Figure 29: In-Line Tensioner . 30Figure 30: Systems Hydraulic Cylinders . 31Figure 31: Hydraulic Joystick Controller . 32Figure 32: Flow Divider Cross-Sectional View. 33Figure 33: Example of Parker Commercial Grade hydraulic Hose . 34Figure 34: Example of Parker O-Ring Style Fittings. 34Figure 35: 2-Groove Pulley Solid Model. 35Figure 36: 2-Groove Pulley Plaster Prototype . 36Figure 37: 2-Groove Pulley CNC Machined . 36Figure 38: Assembly of the Bucket . 37Figure 39: Milling Operations used for the Bucket . 37Figure 40: Picture of Completed Prototype During Rolling Testing . 38Figure 41: Tractor During Full Load Test . 39v
LIST OF TABLESTable 1: Interview InformationTable 2: Initial Customer FeaturesTable 3: Scheduled TasksTable 4: Proposed Budget OverviewTable 5: Actual Budget, Condensed28414243vi
ABSTRACTThis is a Report and Design Project that has been developed to aid homeowners in theirlandscaping needs. What developed was a proposal for a Hydraulic Front-End Bucket Loaderprototype. This prototype was created to help eliminate the need for an added machine andexpense to a homeowner. This Front-End Loader will be fastened on to the existing frame ofa personal lawn tractor while minimizing modification to it. The hydraulic and mechanicalcomponents of the prototype will be bolted on to the existing frame and chassis components.The use of light weight material, strong steel joints and bushings allow for the loader to outpreform the current markets competition. One of the largest benefits to this design is that itallows for the mower desk to stay attached to the tractor while providing “Quick Disconnect”features. The quick disconnect features allow for one person operation and storage. Theloader arm and bucket assemblies are completely detachable from the tractor.This Prototype also allows for a greater load capacity and lift range. The load capacity is350lb and has enough lift to be able to put loads of mulch, soil and gravel into a ¼ ton pickuptruck. The market comparisons for this size tractor are very different. They only allow for amaximum load of 150lb and lift height of 5-10 inches. This type of minimal load capacityand lift features limits the homeowner’s ability to perform normal landscaping task.Currently, if you want a greater load capacity and lift height you have to purchase a separatemachine to do the job. Normally, this extra machine would be much larger in size and maybecome costly to maintain. This is why this Design Project was developed. Thus, theprototype assists in the elimination of extra storage space and added cost to the homeowner.All of the components, mechanical and hydraulic, have been developed for a Craftsman/Husqvarna series lawn tractor (Craftsman Model #07128857000, Mfr. model #28857). Yet, itis possible to modify and attach this prototype to three (3) other tractor models.This particular Craftsman Lawn Tractor has a Hydrostatic driveline and integrated safetyfeatures. The beauty of the Loaders Hydraulic System is that it works simultaneously withthe tractors driveline. Yet, the sealed hydraulic system functions completely independentfrom it. Another great feature of the hydraulic system is that it utilizes that the sameintegrated safety features of tractor. Thus, this eliminates the need for additional wiringcomplexity and mechanical safety features that would add expense, weight and complexityfor the home own to maintain.The hydraulic system utilizes O-Ring seals to help eliminate the potential for leaks andcontamination of the systems. It also has a single joystick controller to allow the operator tofocus on the loading system. The system also, has integrated “Dripless” hydraulic disconnectfittings. This not only eliminates potential contamination and lost oil from the system but,also helps to keep the environment free of added contaminates.This Design Project has many components to it but, the single most important item is that itperforms. Testing proves that the system completes the tasks and features that it has defined.vii
Front End Hydraulic Loader for a Lawn TractorAdam DehnePROBLEM DEFINITION AND RESEARCHPROBLEM DEFINITION AND BACKGROUNDSome lawn tractors today have hydraulic drive systems and it would great to tap into thatsystems or create one, for other hydraulic applications. Two versatile applications would be afront-end scoop loader and a snow plow. There are smaller commercial machines that dothese functions but, are very expensive for a normal home owner to acquire.The proposal is to fabricate a prototype hydraulic front-end loader system (perhaps even beable to attach other attachments such as a power auger for homeowners to put in fence post,footings, irrigation heads and more) that will be mounted onto a personal lawn tractor.There are two main portions/systems of this project. These systems will include the hydraulicdistribution lift system and controls. The second will be bucket/plow lifting assembles andtractor mounting points.1
Front End Hydraulic Loader for a Lawn TractorAdam DehneRESEARCH-INTERVIEWSA conducted interview with John Dehne (1) took place. He is a corporate engineer who ownsa personal lawn tractor and does a multitude of lawn work at this home. He was interviewedover the phone on September 25, 2011. The features that he felt would be necessary for theloader are as follows.Table 1: Interview InformationCategory Hydraulic and Loader MechanismBucket Snow Plow Feature InformationLoader arms do not need to be able todetachAttachment(s) need to be removableLift: Minimum of 2ft and a Maximumof 5.5ftSize: Under a cubic yardWeight: Under 100lbBucket pitch: 30º parallel to groundPlow movement: Swivel left to right,up and downSkid blade or rollers at bottom ofbladeWeight: Light enough for one personmovementStorage: Plow will be stored when notin use(See Appendix A for more). John was able to provide insight to what a real customer wouldbe looking for when it comes to this front-end loader prototype. He developed three maincategories for the prototype with specific desired features listed above.ONLINE RESEARCH - TECHNOLOGY AND EXISTING PRODUCTSResearch was conducted and as a result 4 main categories were created. Category 1:Hydraulic system capacity/form/function, Category 2: Loader capacity/form/function,Category 3: Bucket capacity/form/function and Category 4: Snow Plowcapacity/form/function. 5 web sites were utilized from the internet. Three sites are forbucket/loader information and two sites refer to snowplow information. Refer to Appendix Afor additional information on the following research objects.2
Front End Hydraulic Loader for a Lawn TractorAdam DehneFRONT-END BUCKET LOADER RESEARCH:The Johnny Bucket Jr. (fig. 1) is anelectric operated front-end bucket that hasa only 200 lbs. load capacity. It attachesto the front most extreme portion to thelawn tractor. One beneficial feature is thatit does not interfere with the mowing deckbut, it lift height capacity is only 10”. Thislimitation is rather significant when tryingto load into a truck bed. The movement ofthe bucket is rather slow. Although, thesystem is light weight and the bucket canswing from 0º (parallel to the ground) 90º (perpendicular to the ground) via apush of a button.Limitations and Advantages:Limitations; lift height, lift capacity, itsFigure 1: Johnny Bucket Jr. (2)non-adjustability, slow moving bucketand there is no way to attach a snow plow to it.Advantages; Moderate weight, Electronic controls, Moderate cost and does not interfere withthe mower deck3
Front End Hydraulic Loader for a Lawn TractorAdam DehneThe Husqvarna Front Scoop (fig. 2) is amechanical, hand lever operated, frontend bucket loader. It attaches to the frontmost extreme portion to the lawn tractor.This system is less expensive than electricand hydraulic by the utilization of simpleto use “man power” lever arms. Thissystem is not adjustable and only has a200lbs. lift capacity. The lift height israther short as well. Maximum lift is 5-7”from the ground. One benefit of thissystem is that it does not interfere with themowing deck.Limitations and Advantages:Limitations; lift height, lift capacity,Figure 2: Husqvarna Front Scoop (3)mechanical lift mechanism, its nonadjustability, many mechanical linkages and there is no way to attach a snow plow to it.Advantages; light weight, low cost and does not interfere with the mower deck.4
Front End Hydraulic Loader for a Lawn TractorAdam DehneThe Koyker Loader Model 50 (fig. 3) is ahydraulic front-end loader that is intendedto be used with lager tractor/lawn tractorand/or tractor/lawn tractor without a bellymounted mowing deck. The load capacityis much greater than intended use. Thereach and lift height are suitable forintended use. The cost is much more thanan electrical loader system. The loaderarms are detachable and the bucket isremovable as well but, is not intended tobe a “quick disconnect” accessory. Thesystems maximum dump angle is 37º andthe digging depth is 3”.Limitations and Advantages:Limitations; non-adjustability, cost, nonFigure 3: Koyker Loader Model 50 (4)quick disconnect accessories, must beused with a larger tractor or with one that has no mowing deck and there is no way to attach asnow plow to it.Advantages; Lift and load capacity is appropriate, bucket reach and lift height is appropriate,sealed hydraulic system5
Front End Hydraulic Loader for a Lawn TractorAdam DehneSnow Plow research information:The Craftsman 14” Snow Blade (fig. 4) isa mechanical (lever arm) snow plowsystem. This snow plow system is notpower and attaches to the front mostextreme portion to the lawn tractor. Itdoes not interfere with the mowing deckand is light weight. The blade can swivelfrom left to right to divert snow. Use of ahand lever is needed to lift/lower plowand a hand grip is used to release a pin sothat the plow may swivel left to right. Theblade/plow is removable with only oneperson for maintenance but, is notintended to be a “quick disconnect”accessory. The scraper blade at thebottom of the plow is removable toreplacement/maintenance.Figure 4: Craftsman 14” Snow Blade (5)Limitations and Advantages:Limitations; mechanical lift mechanism, many mechanical linkages and there is no way toattach a loader bucket to it.Advantages; light weight, low cost, replaceable scraper blade, swivels from left to right anddoes not interfere with the mower deck.6
Front End Hydraulic Loader for a Lawn TractorAdam DehneThe Johnny Snow Plow (fig. 5) is anelectric operated system. This system isintended to be an add-on to the JohnnyBucket Jr. system or can be purchased asa whole system. It attaches to the frontmost extreme portion to the lawn tractor.It does not interfere with the mowingdeck. Its weight is moderate and the plowdoes swivel left-to-right and up and downfor snow diversion. The movement isdone electronically but, is minimal and isslow moving. All of the controls areelectronic and the plow does have aremovable/replicable scraper blade.Limitations and Advantages:Figure 5: Johnny Snow Plow (6)Limitations; lift height, slow movingAdvantages; Moderate weight, swivels from left to right, Moderate cost (is more costly whenpurchased independently from Johnny Bucket Jr. system) and does not interfere with themower deckRESEARCH SUMMARY:The interview and the major systems above, generate information that is used to developspecific customer needs and possible features for this prototype.7
Front End Hydraulic Loader for a Lawn TractorAdam DehneCUSTOMER NEEDS TO ENGINEERED FEATURESCUSTOMER NEEDS/FEATURESInitial customer features, listed below, are needed in order to zero in on what could bepotentially implemented into the design of the front-end loader. Below, in Table 2, are aGeneral List of customer features and a Condensed List to the right of it.These two lists are the building blocks of the future function/features of the prototype. Theleft side list offers ideas of features that could be implemented. These were developed fromresearch and potential personal needed features. The right hand side lists are words and/orphrases that provide parallel thoughts towards the importance of the potential features.Table 2: Initial Customer FeaturesGeneral List: Safety switch- will not be able to operate withoutsitting on tractor Snow plow will have a removal scraper blade Hydraulic lever controlled Easy to operate with simple instructions Be hydraulically driven Wil
Jun 06, 2012 · Front End Hydraulic Loader for a Lawn Tractor Adam Dehne 2 RESEARCH-INTERVIEWS A conducted interview with John Dehne (1) took place. He is a corporate engineer who owns a personal lawn tractor and does a multitude of lawn work at this home. He was interviewed over the phone on September 25, 2011. The features that he felt would be necessary for the
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