Mounted truck bed rack system - UC DRC Home

MOUNTED TRUCK BED RACK SYSTEM
A Baccalaureate thesis submitted to the
School of Dynamic Systems
College of Engineering and Applied Science
University of Cincinnati
in partial fulfillment of the
requirements for the degree of
Bachelor of Science
in Mechanical Engineering Technology
By:
Fred Rolfes
April 2014
Thesis Advisor: Professor Janak Dave, Ph.D
Mounted Truck Bed Rack System
Fred Rolfes
ACKNOWLEDGEMENTS
First and foremost I would like to thank my family, especially my father for providing
me with the necessary tools and work space for fabrication of this project. I would like to
thank my brother-in-law, Ben Erdman, for providing me with necessary fabrication tools as
well. Both of them allowed this project to be built within the garage space at my house which
sped up the fabrication process. Lastly, I would like to thank Schwab Welding Inc. for
helping me with the welding of necessary parts. Their cooperation and help allowed the
fabrication process to move along promptly and effectively.
i
Mounted Truck Bed Rack System
Fred Rolfes
TABLE OF CONTENTS
ACKNOWLEDGEMENTS ....................................................................................................... I
TABLE OF CONTENTS .......................................................................................................... II
LIST OF FIGURES ................................................................................................................ III
LIST OF TABLES .................................................................................................................. III
INTRODUCTION AND RESEARCH ..................................................................................... 4
PROBLEM STATEMENT........................................................................................................................................4
INTERVIEWS ....................................................................................................................................................... 5
CURRENT PRODUCTS ........................................................................................................................................... 6
HARD FOLDING TRUCK BED COVER AND SLIDING RACK SYSTEM .....................................................................6
RACK-IT ............................................................................................................................................................. 7
PRO-SERIES HEAVY DUTY LADDER RACK ............................................................................................................8
CUSTOMER FEEDBACK AND OBJECTIVES .................................................................... 9
SURVEY ANALYSIS .............................................................................................................................................9
PRODUCT FEATURES AND OBJECTIVES ............................................................................................................. 10
ENGINEERING CHARACTERISTICS ..................................................................................................................... 11
DESIGN .................................................................................................................................. 12
DESIGN ALTERNATIVES .................................................................................................................................... 12
DESIGN SELECTION .......................................................................................................................................... 15
DRAWINGS ........................................................................................................................... 16
LOADING CONDITIONS ..................................................................................................................................... 17
COMPONENT SELECTION .................................................................................................................................. 18
DESIGN ANALYSIS ............................................................................................................................................ 19
BILL OF MATERIALS ......................................................................................................................................... 20
SCHEDULE AND BUDGET ................................................................................................. 21
SCHEDULE ........................................................................................................................................................ 21
BUDGET ............................................................................................................................................................ 22
FABRICATION AND TESTING .......................................................................................... 23
FABRICATION ................................................................................................................................................... 23
TESTING ........................................................................................................................................................... 24
WORKS CITED ..................................................................................................................... 26
APPENDIX A - RESEARCH................................................................................................. 27
APPENDIX B – SURVEY WITH RESULTS ....................................................................... 31
APPENDIX C – QUALITY FUNCTION DEPLOYMENT QFD ......................................... 32
APPENDIX D – OBJECTIVES ............................................................................................. 33
APPENDIX E – PROOF OF DESIGN ................................................................................... 34
ii
Mounted Truck Bed Rack System
Fred Rolfes
APPENDIX F – ASSEMBLY INSTRUCTIONS .................................................................. 35
APPENDIX G – SHOP DRAWINGS AND FINAL ASSEMBLY ....................................... 36
LIST OF FIGURES
Figure 1 – Bak Industries Folding Truck Bed Cover and Sliding Rack System ...................... 6
Figure 2 – Rack-It system ......................................................................................................... 7
Figure 3 – Pro-Series Heavy Duty Ladder Rack ...................................................................... 8
Figure 4 – Concept #1 ............................................................................................................. 12
Figure 5 – Concept #2 ............................................................................................................. 13
Figure 6 – Concept #3 ............................................................................................................. 14
Figure 7 – Isometric Assembly View ..................................................................................... 16
Figure 8 – Loading Conditions ............................................................................................... 17
Figure 9 – Square Tube Aluminum ........................................................................................ 18
Figure 10 – Angle Aluminum ................................................................................................. 18
Figure 11 – Finite Element Analysis ...................................................................................... 19
Figure 12 – Rack with 560 lb load applied. ............................................................................ 24
LIST OF TABLES
Table 1 – Survey Results .......................................................................................................... 9
Table 2 – Engineering Characteristics .................................................................................... 11
Table 3 – Selection Method .................................................................................................... 15
Table 4 – Bill of Materials ...................................................................................................... 20
Table 5 – Schedule .................................................................................................................. 21
Table 6 – Budget ..................................................................................................................... 22
Table 7 – Assembly Test Times.............................................................................................. 25
iii
Mounted Truck Bed Rack System
Fred Rolfes
INTRODUCTION AND RESEARCH
PROBLEM STATEMENT
Truck bed rack systems are very common among pickup truck owners. Company trucks
and work trucks tend to utilize rack systems more often due to the nature of their everyday
hauling needs. While the majority of the current rack systems available suffice individual
hauling needs, the structures are usually welded as a single frame. This design style allows
for a strong durable rack but lacks the option of a quick and simple disassembly, appealing
design, as well as requiring a large storage space if not needed or desired on truck. Generally
company pickup trucks are able to get away with these large and bulky frames. Your average
pickup truck owner who uses their vehicle as a daily driver is looking for a design that will
complement their truck when installed, be easily disassembled when not needed, and capable
of handling all the needs associated with hauling longer cargo on a self installed rack system.
The proposed design and build of a new mounted truck bed rack system will bring
functionality and style to appeal to the average pickup truck owner. The product will meet
the needs of the customer by providing a design that specifically tailored around simplicity
functionality, and design appeal. The product will be quick and easy to install and assemble,
as well as dissemble when not needed or desired. It will have an appealing design that
includes low profile mounting brackets. The product will also have great durability and
strength to handle all of the needs associated with hauling longer cargo on a self-installed
rack system. This cargo will be specific to objects potentially longer than the owner’s bed
(ladders, lumber, piping, etc.)
4
Mounted Truck Bed Rack System
Fred Rolfes
INTERVIEWS
Bob Bruner likes the concept of a more compact design for a truck bed organizer. He
believes that many companies are in fact using your everyday pick truck to carry out their
daily work and this project could greatly aid workers, as well as the everyday truck owner.
He wanted me to be sure to focus on the simplicity and ease of the installation as well as the
overall compact design. (1)
Fred Rolfes Sr, works within the construction field and uses his truck for hauling cargo
every day. He currently does not own a bed organizer due to appearance and lack of
versatility for his type of work. He believes a better design would help with the clutter of his
truck bed and significantly help reduce tool and equipment wear if system successfully
organized and secured cargo. (2)
See Appendix A for more detailed and complete research on interviews.
5
Mounted Truck Bed Rack System
Fred Rolfes
CURRENT PRODUCTS
Before beginning the design of this product some background research was conducted in
order to get a good feel for what kind of products were currently on the market. There are
three examples of installable rack systems for trucks listed in this report. They are Hard
Folding Truck Bed Cover and Sliding Rack System, Rack-It, and PRO-SERIES Heavy Duty
Ladder Rack.
See Appendix A for a more detailed and complete research on current products.
HARD FOLDING TRUCK BED COVER AND SLIDING RACK SYSTEM
The first product that was researched was the Hard Folding Truck Bed Cover and
Sliding Rack System. By Bak Industries, the design features a fully sliding rack is combined
with a folding cover (Figure 1). This particular type of system is favored by painters and
those whose jobs require ladders. This design allows for the cross members to be positioned
anywhere along the length of the bed to accommodate varying sizes of ladders as well as
lumber, etc. The folding cover allows for protection from the outdoor elements and debris
(3). This product is rather expensive, which a major downside. It requires the purchase of the
cover as well (comes as a package), which drives the price up. There is also no adjustable
height.
Figure 1 – Bak Industries Folding Truck Bed Cover and Sliding Rack System
6
Mounted Truck Bed Rack System
Fred Rolfes
RACK-IT
The second type of installable rack systems researched was the Rack-It. This product is
mainly common among company work trucks. As discussed earlier these are single frame
units and are excellent for hauling a variety of longer cargo. They are also strong and durable
making them a good fit for heavy duty work equipment. Despite the strength and capabilities
of this style of rack, they still are not usually desired by your everyday pickup truck owner.
They lack an appealing design, are large and bulky, as well as not capable of an easy
disassembly when not desired on truck.
Figure 2 – Rack-It system
7
Mounted Truck Bed Rack System
Fred Rolfes
PRO-SERIES HEAVY DUTY LADDER RACK
The final product I researched was the Pro-series heavy duty ladder rack. This type of
design is very popular due to its ease install and removal. This product allows the owner to
effectively haul longer cargo. The design fits most trucks and allows for the user to install on
either side of the truck bed. It also allows for height adjustment of the uprights. It does
require drilling for installation. The major downside to this style of design is the limiting
amount of cargo you can haul at once as well as the maximum load capacity.
Figure 3 – Pro-Series Heavy Duty Ladder Rack
8
Mounted Truck Bed Rack System
Fred Rolfes
CUSTOMER FEEDBACK AND OBJECTIVES
SURVEY ANALYSIS
The eleven features that were found to be most favored from the research were put into a
survey. The purpose of the survey was to determine the importance of the eleven customer
features that would be designed for in the design and creation of a mounted truck bed rack
system. The ratings were listed from 1-5 with 5 being the most important. It also asked how
much they would be willing to pay for such a system by choosing a dollar amount range, as
well as how satisfied with current product. The survey was handed out to eight pickup truck
owners in order to get reliable results. Table 1 shows that after analyzing the results the top
three features were compact, ease of use, and a tie occurred for weight capacity and
durability. The cost of how much the respondents were willing to pay for the system in
question came to be $500-$1000.
See Appendix B for a detailed and complete survey.
Table 1 – Survey Results
Customer Features
Compact
Ease of Use
Durability
Weight Capacity
Versatility
Range of Operation
Lightweight
Resistance to Outdoor Elements
Appealing Physical Design
Aerodynamic Design
Safety
Customer
Importance
4.8
4.5
4.6
4.8
4.5
4.6
3.5
4.4
3
2.6
3.3
Relative
Weight
14%
13%
11%
11%
11%
10%
9%
8%
7%
6%
5%
The customer features feedback aided in the creation of specific product objectives that
would help me obtain measurable variables to collect data.
9
Mounted Truck Bed Rack System
Fred Rolfes
PRODUCT FEATURES AND OBJECTIVES
Based off of the survey information, the product objectives were created as a list of
features to consider. They are listed below in order of most importance with respect to the
survey. Each productive objective came from the customer features and was converted into
measurable variables.
1. Compact (14%)
-Design will not extend more than 1ft above truck cab.
-Design will not extend more than one inch past original truck bed rails
2. Ease of Use (13%)
-Pin locking system
-Quick disconnects
-No more than x amount of tools required
- Standard tools needed for assembly
3. Versatility (11%)
-Adjustable sliding rack system
-Height adjustment on rack uprights
4. Weight Capacity (11%)
-Capable of holding standard payload of a Dodge Ram 1500
5. Durability (11%)
-Design factor consistent with loading conditions in expected use
-Rust-resistant material for outdoor components
-Corrosion-resistant material
6. Range of Operation (10%)
-Rack system capable of securing cargo taller and wider than bed
-Adjusting components within reach of human factors
7. Lightweight (9%)
-Lightweight aluminum
-Minimal components
8. Appealing Physical Design (7%)
-Sleek design
9. Aerodynamic Design (6%)
-Wind reducing design to reduce wind drag
-Wind deflectors to reduce noise
10. Safety (5%)
-Locking components
-Stable frame when mounted
10
Mounted Truck Bed Rack System
Fred Rolfes
ENGINEERING CHARACTERISTICS
The product objectives were then used to develop a Quality Function Deployment chart.
A Quality Function Deployment chart used in order to visually see the weighted importance
of each aspect of the design. The design multiplier was justified off certain customer features
that I viewed as most important from an engineering standpoint. This view caused the
greatest impact in relative importance. Table 2- below shows this weighted importance in
order of most important to least important.
See Appendix C for a detailed and complete QFD.
Table 2 – Engineering Characteristics
Engineering
Characteristics
Relative
Importance (%)
Storage Capacity
Size
Weight
Material
Truck Bed Size
Finish/Color
Standard Components
Manufacturability
Installation Time
23
19
18
16
8
6
6
2
2
11
Mounted Truck Bed Rack System
Fred Rolfes
DESIGN
DESIGN ALTERNATIVES
During the design process, three separate concepts were created an analyzed. This
allowed for an effective way to choose the most suitable design for the product. Advantages
and disadvantages were generated and used in the decision process. Below are the three
separate design concepts.
Vertically Folding Securing Post Design
Figure 4 – Concept #1
This design featured four posts mounted at each corner of the truck bed. The posts would
be mounted inside the bed and would be hinged so that they could fold up. They would have
three separate locking positions. The first would be the unopened position where it would be
within the bed of the truck. The second position would be locked at 90 degrees. This position
would allow for hauling of long cargo. The third position would be locked at 180 degrees
allowing for additional elevated tie down points. The downsides to this design are that the
posts limit the bed area when unopened and there is a limit to the length of cargo capable of
being hauled due to the height of the posts.
12
Mounted Truck Bed Rack System
Fred Rolfes
Rail Bracket Design
Figure 5 – Concept #2
This design concept involves four brackets that get mounted to the bed rails by drilling
holes and using fasteners. The mounting brackets would be low profile and also include the
vertical post holder which would sit below the truck bed rail on the inside of the bed. The
four vertical posts get assembled into the post holders. Two cross bars would then be locked
in place with locking pin at the front and rear posts. This design allows for longer cargo to be
effectively hauled and it allows for a quick and easy assembly/disassembly. Some downsides
are the need for drilling and potential heavy product weight.
13
Mounted Truck Bed Rack System
Fred Rolfes
3 Point Folding Rack System
Figure 6 – Concept #3
The third design concept utilizes a three point folding front rack, and an upward sliding
rear rack. The front rack would consist of a folding and locking frame that will be able to
easily opened and closed. The rear rack will consist of two post holders that will house the
frame. The frame will be able to be pulled up and locked in place at a desired height to
complete the whole rack system. This system is also capable of hauling longer cargo. The
downside to this design is the difficulty of making the three point folding front rack. This
would most likely be bulky and potentially difficult for a single person to operate. In the
unopened position, this design would also limit the truck bed area.
14
Mounted Truck Bed Rack System
Fred Rolfes
DESIGN SELECTION
In order to select the concept that best fit the customer requirements, a Weighted Method
was utilized. As shown in the table below, weights were given to each of the characteristics
and then based on the design a numerical value was assigned to each design. These values
were then multiplied by the weight and then summed up in order to calculate the total weight.
As shown in the Table-3, the Rail Bracket concept was chosen as it had the highest weighted
total.
Table 3 – Selection Method
Evaluated
Characteristics
Weighted Rated Method (0-4)
Designs
Vertically Folding
Flip Out Sidewall
Weights
Secure Posts
Mount
Rail Bracket
Design
Compact Design
0.25
3
3
4
Ease of Use
0.25
4
4
4
Versatility
0.20
3
2
3
Weight Capacity
0.15
4
4
4
Range of Operation
0.15
2
2
2
Weighted Total
1.00
3.25
3.05
3.35
15
Mounted Truck Bed Rack System
Fred Rolfes
DRAWINGS
Isometric Assembly View (Truck bed omitted for clarity):
Figure 7 – Isometric Assembly View
The above picture is of the final assembly of the rack model that was designed in
SolidWorks. It shows the product with the black finish that will be applied to the product at
the end of the fabrication.
16
Mounted Truck Bed Rack System
Fred Rolfes
LOADING CONDITIONS
Figure 8 – Loading Conditions
The loading conditions were developed from the research of other products and then chosen
for the proof of design. The design called for maximum load capacity of 500 lbs.
17
Mounted Truck Bed Rack System
Fred Rolfes
COMPONENT SELECTION
The material selected for this project is 6061 T6 Aluminum. This material was selected
due to its durability, good surface finish, high corrosion resistance, and is readily suited for
welding. Fabrication of 6061 aluminum is excellent and is suitable for conventional welding
methods. Extrusions are available in a multitude of types including: square box, rectangular
square box, channel, equal angle, and unequal angle, flat bar, and tube. This design will
utilize the aluminum square tubing for the posts and crossbars, and angle bars for the rail
mounting brackets. Total weight of product is calculated to be around 55 lbs.
Figure 9 – Square Tube Aluminum
Figure 10 – Angle Aluminum
18
Mounted Truck Bed Rack System
Fred Rolfes
DESIGN ANALYSIS
The design analysis was conducted through a Finite Element Analysis (FEA) of the
model that I created in SolidWorks. The FEA results showed that the end of the crossbeams
were under the greatest amount of stress at around 3,000 psi. Initially, I had assumed that the
brackets would be under the greatest stress but the results showed that they were not. The
brackets topped out around 1,100 psi. The material that was selected for this design has
tensile yield strength of 40,000 psi and a tensile strength of 45,000 psi. Figure 11 shows the
FEA results and the associated color coordinate key.
Figure 11 – Finite Element Analysis
19
Mounted Truck Bed Rack System
Fred Rolfes
BILL OF MATERIALS
Table-4 includes all of the materials that were used in the fabrication of this product.
Table 4 – Bill of Materials
Quantity
8
8
8
8
8
8
4
4
4
2
Item
Bolt
Bolt
Nut
Nut
Washer
Washer
Pin
Vertical Post
Cross Bar
Bracket
Description
Hex Head 1/2 -13 x 1.5 in.
Hex Head 3/8 -13 x 1.5 in.
Hex Nut 1/2-13
Hex Nut 3/8-13
Type A Flat 1/2 in.
Type A Flat 3/8 in.
Locking Pin 3/8 x 3.75 in.
Aluminum 6061 T6 Square Tubing 2.5 x 2.5 x 1/4 x 36 in.
Aluminum 6061 T6 Square Tubing 2 x 2 x 1/4 x 72 in.
Aluminum 6061 T6 Square Tubing 3 x 3 x 1/4 x 10 in.
20
Mounted Truck Bed Rack System
Fred Rolfes
SCHEDULE AND BUDGET
SCHEDULE
The full schedule of this project measures 28 weeks long. Between these dates Table 3 –
Schedule shows the scheduling of designing, modeling, ordering, assembling, and testing
with a break towards the middle. The yellow represents the estimated schedule times
developed at the beginning of the process and the blue represent the actual.
Apr 20 - 26
Apr 13- 19
Apr 6 - 12
Mar 30 - Apr 5
Mar 23 - 29
Mar 16 - 22
Mar 9 - 15
Mar 2 - 8
Feb 23 - Mar 1
Feb 16 - 22
Feb 9 - 15
Feb 2 - 8
Jan 26 - Feb 1
Jan 19 - 25
Jan12 - 18
Jan 5- Jan 11
Dec 29 - Jan 4
Dec 22 - 28
Dec 15 - 21
Dec 8 - 14
Dec 1 - 7
Nov 24 - 30
Nov 17 - 23
Nov 10 - 16
Nov 3 - Nov 9
Oct 27 - Nov 2
Oct 20 - 26
Oct 13 - 19
TASKS
Content review (advisor)
Oct 6 - 12
Name: Fred Rolfes
Project title: Mounted Truck Bed
Rack
Sep 29-Oct 5
Table 5 – Schedule
9
Proof of Design Agree (advisor)
Concepts/Selection (advisor)
3D Model - (Rear Frame Sub-assembly)
3D Model - (Front Frame Sub-assembly)
3D Model - (Final Unit Assembly)
Design Analysis
25
1
8
23
6
13
Bill of Materials
5
Design Pres to Faculty (12 mins)
Design Report Due to Advisor
Order Parts
Shop Drawing
Fabrication
Assembly
Test Unit
17
28
7
14
20
25
6
Modifications
20
Final Testing
20
Advisor Demonstration
Expo
Project Presentation to Faculty
Project Report to advisor for review
Library pdf file in BB (fall course link) Wed April 23
28
3
11
18
23
21
Mounted Truck Bed Rack System
Fred Rolfes
BUDGET
The budget is a list of every expense that is involved with the project. The total cost to
design and build the product is estimated to be around $400. At the completion of the project
the total expenses were calculated and came out to be around $435. This amount is slightly
higher than the forecasted amount before this project was built.
Table 6 – Budget
Materials, Components or Labor
Forecasted
Amount
Actual
Amount
Frame (Aluminum square tubing)
$200.00
$ 320.00
Fasteners (Nuts/bolts, washers)
$100.00
$30.00
Misc. services/parts (welding shop, paint, saw
blades, grinding wheels)
$100.00
$ 85.00
Total
$400.00
$435.00
22
Mounted Truck Bed Rack System
Fred Rolfes
FABRICATION AND TESTING
FABRICATION
The fabrication of this product was completed in (3) main phases.
Phase 1:
• Cut all necessary stock aluminum tubing to size per shop drawings.
- (4) Rail Brackets
- (4) Post Holders
- (4) Posts
- (2) Crossbeams
• Deburred all material that had been saw cut.
• Drilled holes in mounting rail brackets per shop drawings.
• Deburred all material that had been drilled.
• Completed fabrication of rail brackets
- MIG welding of Rail Bracket to Post Holder per shop drawing.
Phase 2:
• Drilled pin locking thru holes for (4) vertical posts per shop drawing.
• Deburred all material that had been drilled.
• Notched out tops of (4) vertical posts per shop drawing. .
- Saw cut initial notch
- Angle grinded to rough finish
- Hand grinded to smooth finish
• Grinded fitting ends of vertical posts and crossbeams.
- Angle grinded to rough finish
- Hand grinded to smooth finish
Phase 3:
• Prepped surfaces for painting.
- Final deburring
- Used steel wool on all surfaces
- Washed and dried all surfaces.
• Painted
• Mounted (4) rail brackets to truck bed per assembly directions. See Appendix F.
• Inserted (4) vertical posts into corresponding front and rear post holders assemblies.
• Inserted (2) crossbeams into corresponding front and rear post holders assemblies.
23
Mounted Truck Bed Rack System
Fred Rolfes
TESTING
The final completed product was put through two main tests that included a load test as well
as a timed assembly test. These tests were implemented in order to verify the final product
was conforming to the proof of design.
Load Test
Purpose:
The purpose of this test is to prove the design requirement of the rack system holding up to
500lbs. The completed project was mounted onto a Dodge Ram 1500 pickup truck, truck the
project was designed around. All parts were assembled per installation manual. The test
involved the loading and unloading of the rack system with design requirement weight of 500
lbs, and then exceeding that with a final weight of 560 lbs. A successful test would result in
no deformation of the frame and no collapse of frame while equipped with the load.
Test Procedure:
In order to achieve the desired weight, 80 lb QUIKCRETE concrete mix bags were used. In
order to create an effective holder for the concrete bags, two boards were placed on the rack
to create a base for the bags to rest on. A total of 6 bags were first placed upon the boards, for
a total weight of 500lbs. A final bag was placed on the system resulting in a total of 7 bags at
560lbs.
Test Results:
After the load was applied and taken off there was no visible signs of deformation or collapse
of the frame resulting in a successful test.
Figure 12 – Rack with 560 lb load applied.
24
Mounted Truck Bed Rack System
Fred Rolfes
Assembly Test
Purpose:
The purpose of this test is to prove that the assembly time for this project meets the predetermined design requirement of equal to or less than 30 minutes.
Test Procedure:
In order to achieve an effective result (5) separate truck owners were asked to assemble this
product per to the directions given provided to them. (Note: Testers were instructed to begin
assembly at step 2 of the instruction manual.) Each period was timed with a stop watch.
These times were recorded and then averaged together to obtain and accurate result.
Test Results:
Table 7 – Assembly Test Times
Assembly Test Times
Tester
Time (minutes)
21.97
1
24.14
2
22.43
3
23.61
4
20.54
5
22.54
Average
The above table shows the averaged times from the assembly test. The testing proved that the
product adequately met the design requirement of having an assembly time of no more than
30 minutes.
Assembly directions provided in Appendix F
25
Mounted Truck Bed Rack System
Fred Rolfes
WORKS CITED
1. Bruner, Bon. Manager/Owner of Cincy Tool Rental. Cincinnati, September 27, 2013.
2. Sr., Fred Rolfes. Potential Customer. Cincinnati, September 28, 2013.
3. bakindustries.com. Bak Industries. [Online] Bak, 2013. [Cited: September 5, 2013.]
http://bakindustries.com/p-8200-bakflip-cs-tonneau-cover-rack-combo-review.html.
4. rackitinc.com. [Online] [Cited: September 5, 2013.]
http://www.rackitinc.com/truckracks/aluminumracks.html
5. homedepot.com. [Online] Home Depot . [Cited: September 5, 2013.]
http://www.homedepot.com/p/PRO-SERIES-Heavy-Duty-Single-Sided-Ladder-Rack-forTrucks-HTMULT/100645160#product_description
26
Mounted Truck Bed Rack System
Fred Rolfes
APPENDIX A - RESEARCH
Interview with industry expert: Bob Bruner of Cincy Tool Rental
3741 Warsaw Ave, Cincinnati, OH 45205 08/27/13
He has 20+ years in the tool and equipment rental business. Company does
self-rental pickups as well as delivery rental for an array of equipment ranging
from shovels to lawnmowers, generators to post-hole diggers. He has
practically any equipment or tool for the average do-it-yourself person as well
as daily everyday jobs in the workforce. The vast majority of these tools can be
loaded and transported in your average pick-up truck as I have experienced
from working there myself.
He explained how they use truck bed accessories to aid them in loading,
securing, and transporting their equipment.
They use a mounted rack system that is helpful in properly securing cargo but
not as versatile or compact as the design ideas I was proposing to him.
He felt as if my project would be very helpful to the everyday pickup truck
owner and relieve a lot of stress associated with relying on your own tie down
job without an aid of a mechanical device.
Important features to consider:
 compact,
 easy to use,
 easy to self-install
 versatility
Interview with potential customer: Fred Rolfes Sr. of G&G Langenbrunner
Masonry Inc. 1151 Neeb Road, Cincinnati, OH 45233 08/28/13
He has 20+ years in the masonry and construction business.
He has experience with loading and transporting supplies and equipment daily
to work site in personal pickup truck.
Does not currently own a truck bed rack system because he believes they are
too big and bulky, not compact or versatile enough for his type of work, as
well as not well visually incorporated into the truck when not in use.
Believes a better design would help with the clutter of truck bed and
significantly help reduce tool and equipment wear if system successfully
organized and secured cargo.
Important features to consider:
 Compact
 Lightweight
 Appealing design
 Durability
27
Mounted Truck Bed Rack System
Bak Industries Hard Folding Truck Bed Cover and
Sliding Rack System
The Bak truck bed system is an integrated sliding rack and
folding cover all in one for truck owners to self-install.
Used for loading, locking, stacking, and hauling cargo. The
sliding rail system allows for the rack to be positioned
anywhere along the length of the rails. It features a sliding
loading lock that inserts into the extruded cross members of
the rack allowing for a secure grip for ladders, dry wall, etc.
Fred Rolfes
- Besides a sliding rack
system, another compact yet
versatile grounded floor
securing system could be
implemented for objects that
cannot be put on rack.
- The size and weight could
be reduced to become more
compact and light.
- Main supports do not fold
down.
- Very industrial looking.
- Lacks versatility for other
equipment.
- $1360 USD
Features:

Panel exterior: Aluminum

Panel core: EPS

Panel frames: HD Aircraft Grade Aluminum Finish: Black
Powder Coat

Thickness: 5/8 inch

Hinge: Corrosion Proof EPDM Rubber

Cover Weight rating: 400 LBS. (evenly distributed)

Rack Uprights: Stainless Steel

Cross Members: Aluminum

Rack Finish: Black Powder Coat

Rack Weight Rating: 500 LBS.

Size of box: 68x22x8

Weight of box: 60 LBS

Install tools: 1 x 15mm wrench

Maintenance: 3M Formula 303 UV Protection

Warranty: 2 years
http://bakindustries.com/p8200-bakflip-cs-tonneaucover-rack-comboreview.html
9/5/13
28
Mounted Truck Bed Rack System
Fred Rolfes
Rack-It System
The Rack-It is a durable one piece design. Custom build
for any truck model. Lightweight aluminum construction
makes it preferred over a steel frame. Multiple welded tie
down points.
- Rack can be removed but as
a single frame it takes more
than one person. Storage could
also be an issue.
- Bulky and unappealing
design.
- Starting at $899USD
Features:










One-piece, fully-welded design for MAXIMUM STRENGTH
Make and model specific racks are CUSTOM BUILT for your
truck
Schedule 40 Aluminum pipe construction
Typically rack weighs 75 pounds - about half the weight of a
steel rack
Full-length aluminum angle mounting provides unmatched
structural support and helps distribute weight evenly on your
truck's bedrail
Removable rear bar equipped with quick release "D-Clip" pins
allows flexibility handling for taller loads
Heavy duty boat cleat tie down system
Gussets at the cross bars and overhang provide maximum
structural integrity
NO DRILL MOUNTING available via our MEGA CLAMP
accessory item
Rack finished with an industrial grade "sport" silver powder coat
finish
http://www.rackitinc.com/truc
kracks/aluminumracks.html
9/5/13
29
Mounted Truck Bed Rack System
Pro-Series Heavy Duty Ladder Rack
This product design allows for an effective way to carry
longer cargo. The design allows for the product to be
installed on most makes and models of trucks. It includes
an adjustable height feature to accommodate use on
different trucks as well.
Fred Rolfes
- Not a damage free
installation design.
- Limited cargo hauling
capabilities.
- Relatively cheap
-Limited load capacity (Not
for heavy duty hauling)
- $119 USD
Features:






250 lbs. load capacity
Constructed of 2 in. tubular steel
Telescoping support arms adjust from 19 to 32 in.
deep and tilts 0 or 20 degrees
Individual front and rear racks support extension
ladders, deck boards and more
Heavy-duty powder coat paint finish resists
scratches and rust
Easy to install and remove
p/PRO-SERIES-Heavy-DutySingle-Sided-Ladder-Rackfor-TrucksHTMULT/100645160#produc
t_description
09/5/13

30
Mounted Truck Bed Rack System
Fred Rolfes
APPENDIX B – SURVEY WITH RESULTS
MOUNTED TRUCK BED ORGANIZER
CUSTOMER SURVEY
Many pickup truck owners do not own mounted truck bed organizing units due to their lack
of physical and appeal as well as a single bulky frame. This product will serve to improve
functionality and improve upon physical design with regards to the truck.
Survey results will be used to best aid the design process of this product.
How important is each feature to you for the design of a new truck bed organizer?
Please circle the appropriate answer. 1 = low importance
5 = high importance
Durability
Resistance to Outdoor Elements
Weight Capacity
Aerodynamic Design
Appealing Physical Design
Lightweight
Compact
Versatility
Ease of Use
Range of Operation
Safety
1
1
1
1(1)
1(1)
1
1
1
1
1
1
2
2
2
2(3)
2(2)
2(1)
2
2
2
2
2(2)
3
3
3
3(2)
3(2)
3(3)
3
3
3(1)
3
3(2)
4(3)
4
4(2)
4(2)
4(2)
4(3)
4(2)
4(4)
4(2)
4(3)
4(4)
5(5)
5
5(6)
5
5(1)
5(1)
5(6)
5(4)
5(5)
5(5)
5
11%
8%
11%
6%
7%
9%
14%
11%
13%
10%
5%
How satisfied are you with the current truck bed organizer process?
Please circle the appropriate answer.
1 = very Unsatisfied
5 = very satisfied
Durability
Resistance to Outdoor Elements
Weight Capacity
Aerodynamic Design
Appealing Physical Design
Lightweight
Compact
Versatility
Ease of Use
Range of Operation
Safety
1
1
1
1(1)
1
1
1
1
1
1
1
2
2
2(1)
2(4)
2(4)
2(2)
2(1)
2(1)
2(2)
2
2
3(4)
3
3(3)
3(3)
3(2)
3(6)
3(6)
3(4)
3(5)
3
3
4(3)
4
4(1)
4
4(2)
4
4(1)
4(2)
4(1)
4
4
5(2)
5
5(3)
5
5
5
5
5(1)
5
5
5
11%
8%
11%
6%
7%
9%
14%
11%
13%
10%
5%
How much would you be willing to spend for this project?
$50-$100
$100-$200
$200-$500
$500-$1000
$1000-$2000
31
Mounted Truck Bed Rack System
Fred Rolfes
Relative weight %
1.3
1.1
1.3
1.3
1.5
1.5
1.7
1.5
1.7
1.3
0.8
Relative weight
5
4
5
3
4
4
5
5
5
4
3
Modified Importance
3.75
3.63
3.75
2.25
2.75
2.75
3
3.38
2.88
3.13
3.63
Improvement ratio
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
Planned Satisfaction
Current Satisfaction
Durability
3
3 9
9
4.6
Resistance to Outdoor Elements
3
9 3
3
4.4
Weight Capacity
3 3 3 3
3 9 4.8
Aerodynamic Design
1
3 9 3
3 1 3 2.6
Appealing Physical Design
9
3 3
1 3
3 3
Lightweight
9 3 9 9
1
3 3.5
Compact
9 1 3
3 9 4.8
Versatility
9 2 3
9 9 4.5
Ease of Use
3 3 9 3
3
9 4.5
Range of Operation
3
9
3 9 4.6
Safety
3 3 9 9 1
1
9 3.3
Abs. importance
5.23 1.73 5.09 4.37 0.47 0.48 1.73 2.12 6.40 27.6
Rel. importance
0.19 0.06 0.18 0.16 0.02 0.02 0.06 0.08 0.23 1.0
Designer's Multiplier
Customer importance
Storage Capacity
Truck Bed Size
Finish/Color
Installation time
Manufacturability
Material
Weight
Standard Components
Fred Rolfes
Mounted Truck Bed
Organizer
9 = Strong
3 = Moderate
1 = Weak
Size
APPENDIX C – QUALITY FUNCTION DEPLOYMENT QFD
6.2 0.11
4.8 0.08
6.3 0.11
3.5 0.06
4.4 0.07
5.1 0.09
7.9 0.14
6.7 0.11
7.8 0.13
5.9 0.10
2.7 0.05
58.6 1.0
11%
8%
11%
6%
7%
9%
14%
11%
13%
10%
5%
1.0
32
APPENDIX D – OBJECTIVES
Product Objectives
1. Compact (14%)
-Design will not extend more than 1ft above truck cab.
-Design will not extend more than one inch past original truck bed rails
2. Ease of Use (13%)
-Pin locking system
-Quick disconnects
-No more than x amount of tools required
- Standard tools needed for assembly
3. Versatility (11%)
-Adjustable sliding rack system
-Height adjustment on rack uprights
4. Weight Capacity (11%)
-Capable of holding standard payload of a Dodge Ram 1500
5. Durability (11%)
-Design factor consistent with loading conditions in expected use
-Rust-resistant material for outdoor components
-Corrosion-resistant material
6. Range of Operation (10%)
-Rack system capable of securing cargo taller and wider than bed
-Adjusting components within reach of human factors
7. Lightweight (9%)
-Lightweight aluminum
-Minimal components
8. Appealing Physical Design (7%)
-Sleek design
9. Aerodynamic Design (6%)
-Wind reducing design to reduce wind drag
-Wind deflectors to reduce noise
10. Safety (5%)
-Locking components
-Stable frame when mounted
33
APPENDIX E – PROOF OF DESIGN
Proof of design: Mounted Truck Bed Rack System
The following criteria will be met upon Proof of Design:
1. Compact Design
a. The design will fit in a dodge ram 1500 with dimensions approximately: 76.3’’tall
66.4’’ wide 20.1” deep.
b. Standard tools for assembly (no additional tools needed to carry on board)
2. Ease of Use
a. Installation time of no more than 30 minutes.
3. Versatility
a. Sliding lock in strap rail to extend the length of the bed 76.3’’.
b. Height adjustments will extend no more than 1 ft. above truck roof.
4. Weight Capacity (Rack and Strap System)
a. Rack System capable of supporting up to 300lbs.
b. Strap System capable of supporting up to 500lbs
5. Durability
a. Design life cycle of approximately 10 years
6. Range of Operation
a. Adjusting components within reach of standard human factors
b. 1 person required for operation and assembly
________________________________
Prof. Janak Dave
______________________________
Fred Rolfes
34
APPENDIX F – ASSEMBLY INSTRUCTIONS
Tools Needed:
 Drill with 1/2” and 3/8” bits
 7/16 wrench
 5/8 wrench
Hardware Included:
 (4) vertical posts
 (2) crossbars
 (4) rail mounts
 (8) count 1/2” x 1-1/2” bolts
 (8) count 3/8” x 1-1/2” bolts
 (8) count 1/2” flat washer
 (8) count 3/8” flat washer
 (8) count 3/8” locking washer
 (4) 3/8” x 1-3/4” locking pin
Step 1:
 Align rail mounts to desired position on truck bed rails. Be sure to double check when
measuring to ensure that both sides will line up correctly. Be sure to position rail
mounts so the post holder is sitting within the truck bed.
 After positioning rail mounts to desired position, mark where the 1/2” holes and the
3/8” holes will be in according to the pre-existing holes present on the rail mounts.
 Drill holes accordingly. Top holes 1/2” bit needed. Side holes 3/8” drill bit but
needed.
 Repeat steps for all 4 rail mounts.
Step 2:
 Position rail mount onto truck bed rail and align with holes that were drilled in step 1.
 Fasten rail mounts to truck bed rails with proper bolts and proper washers.
 Repeat steps for all 4 rail mounts.
Step 3:
 Insert vertical post into previously installed rail mount.
 Be sure to align post so that the pre-existing thru holes are at the top and are
positioned so they run parallel with the truck bed rails.
 Repeat steps for all 4 vertical posts.
Step 4:
 Insert each end of crossbar into front post slots, aligning up the pre-existing holes.
 Insert locking pin thru both the post and crossbar assembly.
 Repeat step on opposite side.
 Repeat steps for rear posts.
35
APPENDIX G – SHOP DRAWINGS AND FINAL ASSEMBLY
36
37
38
39
40