|
|||||||
| Register | FAQ | Members List | Calendar | Search | Today's Posts | Mark Forums Read |
![]() |
|
|
Thread Tools | Display Modes |
|
#1
|
|||
|
|||
|
Howe & Howe? What is the Zen of Design?
Greetings to all as this is my first post here. I used to post on Millerwelds (man do many of their posters seem to hate this forum for some reason) but this is the first time here.
I am just a hobbyist that has learned welding mostly through the school of hard knocks. I have actually enrolled in some classes at a professional school nearby to sharpen the skills and learn all sorts of stuff I dont know now. I am not interested in changing careers from a software engineer so much as I am interested in improving my skills and hobby. I have welded mostly non-critical stuff since I started welding. I have put together my welding table, some metal art and done some repairs and other things. However, I am looking to expand that and get into welding more critical things. Personally I have done Stick and tig welding but didnt really like mig welding much. I just bought a miller syncrowave 200 so that I dont have to go to a friend's shop anymore to weld. Specifically I am interested in renovating pre 60s era RVs as well as designing and building new RVs from the ground up. I would potentially be interested in welding some vehicles as well, perpas even make a dune buggy some day or some other off road vehicle. This requires a whole new level of welding competence I will be trying to get at the courses above what I have done on my own. Anyway this brings me to my question. I am sure that many of you have seen the new show "Howe & Howe Tech" put on by the discovery channel which chronicles the shop of the two guys that designed the Ripsaw and sold it to the military as a UGV. The show is great if you haven't caught it. The two men seem to be fairly well educated but they dont seem to sport advanced degrees in mechanical engineering. Nor do they seem to do a lot of wind tunnel testing, exhaustive mathematical analysis and so on. Yet they make excellently built products good enough to impress the military. This is a common trend I have seen among small shop and hobbyists working on their race car in their shop. Few have advanced mechanical degrees, many are too young to have 20 years of experience in the business so how do they do the design? That is the real pivotal question. How do these people come up with the right design with metal tubing of the right strength in the right area without a squad of mechanical engineers and banks of computers performing complex analysis. This bears directly on my hobby. For example, lets say I want to design a new kind of travel trailer. I would have to order tubing from the manufacturer but how do you know what thickness, what size and so on. A trailer frame is a complex mechanical device that cant be analyzed as simply as a statically loaded I-beam. Of course I could pick materials that are over engineered. For example if building a 30 foot trailer with two axles and a 9000# GVWR I could pick metal that could take a 9000# weight at center with acceptable deflection that wouldn't exceed proportional stress. A 2" x 10" x 1/4" tube would do that just fine but the reality is it would be incredibly over engineered. Perhaps I could have gotten by with a 2" x 4" x 1/4" tube instead. So how is it done gentlemen. Where is the zen of design. I can get out my cad program and draw up models but how do I plan for the right sizes and stresses? Or do people just really over engineer things and say "that's done" ? Thanks for reading my long winded intro, and thanks in advance for any replies. Last edited by kraythe; 01-13-2010 at 05:11 PM. |
|
#2
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
In some things like off road, you can probably take a wild a$$ guess (WAG), bump it for a rough safety factor, build it and see if it brakes and then redo it when it fails. It's a poor way to design something, especially if you want to push the limits, or try and save weight. It's really not an option for thing that go on the road however like trailers and so on.
I hate to say it, it's why we have engineers, and why they make big bucks. Even basic structures are somewhat complex. A simple steel beam in a building takes 6 or 8 equasions to work out beam size, and thats using mostly predeterminded materials. When you start changing material shapes ( I beam vs C channel vs angle iron vs round or square tube), use different material ( mild steel vs alum vs chrome moly vs titanium or specialty high tensile steel (100K+)) and start dealing with complex forces ( changing member angles from 30 deg to 45, lengthening or shortening axle locations on the same frame length) , there's no simple shortcut. There are probably CAD programs designed to do a lot of the number crunching, but you can bet they probably have a minimum 4-5 digit price tags.
__________________
. No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan |
|
#3
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
Quote:
|
|
#4
|
||||
|
||||
|
Re: Howe & Howe? What is the Zen of Design?
Quote:
As to an offroad truck, there are some basic chassis designs that are sort of universal. As to what will hold up to what?? That depends greatly on conditions and the driver, as well as the speed. Most offroad stuff has been redesigned countless times due to trial and error. Build it, break it, build it stronger. If it breaks again, redesign it and then build it again.
__________________
I think she is Bi-polar. She is a bear sometimes. Does this make her a BiPolar bear????
|
|
#5
|
||||
|
||||
|
Re: Howe & Howe? What is the Zen of Design?
Quote:
Or maybe you'd like to put up the financial backing for a trailer company to 'Push the envelope.' If they do, and they are wrong....that trailer will fail and likely kill people when it runs amok on the freeway. Silly people with an education letting it get in the way of smart thinking and common sense yet again.
__________________
I think she is Bi-polar. She is a bear sometimes. Does this make her a BiPolar bear????
|
|
#6
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
Nope, grab a book and learn. I took 4 semesters of basic structures as part of gaining my Bachelors of Architecture. Most of it wasn't to teach us how to do structural design, but give us a basic understanding of just whats involved in engineering members and sizing. The idea was to understand why we need engineers not to teach us to do the design work.
You need at least a basic understanding of whats going on. Why can you build a thin member truss and carry more weight than a thick short I beam? Why can you use less steel by weight with say a 14" I beam, over an 8" one, yet hold up more weight? How much will a certain member flex when it's loaded and is this too much and cause fatigue failures? How much stronger is a tube made of 4030 over one of the same dimensions made of mild steel? What if you used high tensile steel with say 100KSI strength and what happens if you heat treat it? If you change to alum how much taller or thicker will it have to be to have the same strength? What grade of alum are you going to choose? How much weld area is required to withstand the load on the member if you use a 60XX series rod or change to a 70XX or 80XX rod? If you use a 110XX series rod will you be better off or worse with mild steel? Whats the bearing capacity on grade 5, 1/2" bolts in single shear, double sheer in 5/8" steel, and how much stronger would grade 8 bolts be? How many bolts are required to withstand the tensile force on the member? Whats the torque value for those bolts? Whats the minimum edge tear out dimension for those bolts and the pitch and edge distance? I can go on, and these are basic questions just flipping thru my basic structures book for the most part. I can guarantee you that those guys on Howe and Howe after they won their basic contract to refine their design, had an engineer go over the drawings and make changes. And this is for a vehicle thats unmanned and not used on public roads. Thats was part of the "refining" process. One thing to keep in mind also now days is the idea of liability. If you choose to do your own design, expect to spend BIG bucks on your liability insurance as opposed to having an engineer approve plans and you just fab it. If you skip that part and just do it yourself and don't tell the insurance company, expect to be hanging in the breeze if something fails, because they won't cover you. If the engineer signs off on it, it's his @ss thats responsible if the design not the workmanship is at fault.
__________________
. No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan |
|
#7
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
Hi kraythe and Welcome to the Welding Web Family!
Congratulations on your miller welding machine. And about the trailer building, that's where the different trailer plans come in. They(trailer store, engineer,etc) had to do all the study, application, testing before it is put on the market for us to get the right materials and build. I believe, too, that many things were simply improved on from an earlier model that wasn't seen before or somebody wanted a better aspect of it. That's entrepreneurs: "Find a need and fill it!'
__________________
Rodney The blessing of the Lord makes one rich, And He adds no sorrow with it.' Proverbs 10:22 NKJV |
|
#8
|
||||
|
||||
|
Re: Howe & Howe? What is the Zen of Design?
On the subject of Howe & Howe, I did see the episode last night where they are beginning to test a contraption which will be an add on to their rip saw for removing vehicles (with potential IED explosive devices inside) from the roadway. It was a spear which they ram through the car, then shoot about 16 inches of the spear tip (which is attached by chain) into the car, then as they back the ripsaw vehicle up, the tip turns sideways as not to go back through the hole and pull the car from the roadway. I am certain more than one person who saw this thinks that ramming a car with any IED is a BAD idea and a complete hillbilly way of handling an explosive device in the roadway.
I do like the show but those guys need an engineer. My guess is that at some point they will have to hire one. The military will require it or L&I, or their personal insurance. I read Popular Mechanics magazine and last year these guys were featured for the Ripsaw vehicle which is super cool and a great idea, but I suspect they will need to step up their game to stay in business. |
|
#9
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
So the message seems to be universal? Without hiring millions of dollars worth of help, there isnt any point to design or build anything anymore? Lawyers have us so paralyzed that we arent even willing to try anymore? What a sad state of affairs. It makes me wonder why people here weld things for thier own. I mean why bother if it is just to tinker in the garage pretending you are something big? There has to be something more, there have to be people who can cross the street without fear of a lawyer.
But then lawyers have destroyed the school system, educational system, the manufacturing industry in america and everything they can get their hands on. Its only fitting the biggest lawyer group in america, the ACLU, is defending terrorists I suppose. At any rate I supposed if I want to go this route I will have to take some chances on my own, do the best I can and then have a pro look over my plans. I dont have enough money to keep a full time staff engineer to support a hobby and I will be damned if I am going to let the lawyers and do gooders beat me into submission. I will do the best I can and hopefully I can hire an engineer to look it over. But honestly I dont know where I could even find an engineer like that. At any rate I hate to tell you guys something but even if you have an engineer plan it, and design it. ; even if you have a pro welder build it; even if you have an insurance company insure it; they can STILL go after YOU for every penny they can get. The sad fact is that the law is so obtuse and the power of the lawyers so great that they are, in a way, some of the biggest domestic terrorists we have. Perhaps we should all give up, take up knitting and change the name of the forum. Is it too much to ask to find just a few people with the good old fashioned Amercian can-do spirit? Last edited by kraythe; 01-13-2010 at 09:54 PM. |
|
#10
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
Saw the show last night. Parts of it were interesting. Remember, you are only seeing and hearing what the producers want you to see. I have a number of friends and relatives who are engineers. According to them, there is a trend for fabricators to move away from having their own engineering staffs. They use independent engineers or companies that specialize in just the engineering aspects of a project. Frequently, the engineers are off shore (China) never even meeting the fabricators. They exchange information via internet.
|
|
#11
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
Quote:
__________________
. No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan |
|
#12
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
I am not a business, just a regular guy. As for pro welding capability I can do some good welds but I dont have 25 years experience welding on a pipeline or anything. I would assume that welds that were critical could be inspected of course I dont know how much that or the engineer would cost. I just wanted to build something new but I am getting extremely discouraged and just tempted to say to hell with it, go to work, come home and live the life of a drone. I wonder If I will go cradzy first or die of boredom first.
And here all I wanted to do is a custom trailer for myself and my family, maybe some day to make it a business. A trailer built specifically for boondocking and off grid camping as no other has been before. I wonder how much that consulting engineer would be? Probably thousands I imagine and I dont have a budget like that. And more thousands for the inspector on the welds. Leave it up to the cineese to build everyhing for us I guess. American life made in ****ing china. Back to the TV I guess I wonder if I can stomach watching another rerun of MASH. |
|
#13
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
Quote:
How many books have you bought? How much info have you read? When I don't hear what I like I just shut up and get 'er done. I don't try an make every one else feel guilty for not handing me what I don't have. |
|
#14
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
Quote:
Though you do have a point about having it half done. If I hadn't posted all over the internet looking for info I wouldn't feel half as depressed as I do now. Hearing "no" that many times grates on the nerves. |
|
#15
|
||||
|
||||
|
Re: Howe & Howe? What is the Zen of Design?
Quote:
A few years back I needed to subsidize my income and decided to build some utility trailers. I am a welder by trade but designed them myself because they are simple. But after the first few trailers, I called SAE and registered with them and they issued me a World Manufacturer Identifier number (WMI) which was free to do. With that, a business license for my state and an insurance bond, I could build trailers, and stamp a vin number of my own using my WMI numbers. If I was to hire employees, L&I would be involved and it gets a little more in depth but not difficult. It was inexpensive to do and required little or no engineering. Getting legal is something to be done because you have integrity, and as a business, a responsibility to keep the public safe on the roadways. I just wanted to point out the hillbilly engineering of the Howe and Howe crew regarding the 'car piercer'. |
|
#16
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
You're still somewhat missing the point I believe. Lets try and look at this a different way.
Do you need a special suspension? If not, then all you really are designing is a box that you stick on a trailer frame. Almost any flatbed design would work if it's the right size. For the most part that relieves you of most of the problems and design issues that are the big concern. Now if you want to do some funky 4 wheel independent suspension for dragging this trailer rock crawling, thats a bit different. If you want more ground clearance, thats just a matter of picking a different axle/ rim/ tire combo, like those on military trailers. You haven't reinvented the wheel. As far as the engineer's cost, it might be a few hundred or several thousand, depends on how far off mainstream you plan to build this thing. If you want to make it a business at some point, plan to have one look at it. Again, if it's a new box on an existing trailer, this part may not be as critical. As far as inspection. Can you pass a basic cert in all positions for the process you will use? If you can go pass a 6G mig (assuming mig is what you plan to use) test on a regular basis for the material you want to use, you are probably good enough. If not you need more practice or need to learn more. There are all sorts of tests that can be done if required, and done in house. PM sent. .
__________________
. No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan Last edited by DSW; 01-13-2010 at 11:29 PM. |
|
#17
|
||||
|
||||
|
Re: Howe & Howe? What is the Zen of Design?
Quote:
hmm but no television- I do have room for one. but you want something cool? http://www.hackneys.com/mitsu/
__________________
Ed Conley http://www.screamingbroccoli.net/ MM252 MM211 Passport Plus & Spool gun TA 185 Lincoln SP135 Plus- (Gone to a good home) Miller 125c Plasma 120v O/A set SO 2020 bender Beer in the fridge |
|
#18
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
You can start studying CAD and F.E.A. Or do it the old fashion American way*, reverse engineering.
*disclaimer the American way has forever been renamed the Chinese way
__________________
Vantage 500's LN-25's, VI-400's, cobramatics, Powcon inverters, XMT's, 250 Ton pacific 12' press brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. Lincoln idealarc tig 330A with bernard cooler Sync350LX. Miller migs, marvel saws |
|
#19
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
kraythe, I think you can't see the forest for the trees.
I have had a varied and interesting career in the welding trade. I have seen the results of some "home made and handy" projects and some were damn lucky nobody was maimed or killed. I have done x-ray welding on a lot of projects and I can guarantee that there were plenty of engineers involved every step of the way! Lawyers too. Once, in my younger days, I was told to build a vessel to use as a filtering unit. I looked at the plans and voiced my concerns about it being a poor design but was told to make it, "it will be O.K.". Being young and dumb, I did as ordered, even beefed up some of what I thought were the weaker points. As unit was filled with water and pressure was brought up to about 45 PSI things stared to happen fast. It is truly amazing how much steel can move before failure! Bolts stretch and fly apart like bullets! Luckily the bolts gave some relief to the pressure and the pumps were shutdown pronto. People stood around all wide eyed, staring in disbelief. Long story short, bosses decided to consult an engineering firm. Given plans and pressures, they were told that we were lucky to be alive. I was way under with my best guess on what was needed but if I hadn't put in some extra meat where I thought it was needed myself and a few others might not be around today. I did manage to get a raise out of the deal so all was not lost! Quote:
I am confident that you would do the same if somebody's homemade trailer, or whatever, was involved in an accident that affected you or a member of your family.
__________________
“There’s class warfare, all right, but it’s my class, the rich class, that’s making war, and we’re winning.” Warren Buffett American by birth, Union by choice! Boilermakers # 60 America is a Union. |
|
#20
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
Hi kraythe. I think you are doing good. You are looking and asking questions. That's a start. One reason I suggested plans is so that you could look at a trailer similar to the one you have in mind and study it. Keep asking questions, why the brace here? why this size c channel? etc. You could get that started and declare this is my future project. And in the mean time, get to improve on your welding skills and get to know all about your new to you miller machine. Even when you get to the 'trailer built, now what' somebody somewhere can help you through the legal process of getting it registered,etc.
__________________
Rodney The blessing of the Lord makes one rich, And He adds no sorrow with it.' Proverbs 10:22 NKJV |
|
#21
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
Quote:
.
__________________
. No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan |
|
#22
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
Quote:
I just love the attitude of "yeah these guys sold a major product to the military, broke ground on several innovations and ended up getting a discovery channel show on it; but they are a bunch of hillbilly morons that dont know crap." What arrogance! And people think I am arrogant for wanting to build a damn trailer. Amazing. Yeah I suppose I am a little punchy but the "cant do" without a union shop and 50 lawyers attitude is really pissing me off. And people wonder why the manufacturing is moving to china? Because maybe we have collectively as a manufacturing culture lost our balls. |
|
#23
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
Quote:
I actually personally know someone who got a Discovery Channel show. He's a good friend of mine. He's one of the hosts, he gets to live his dream job, doing things he loves and getting paid for it. He's a great guy, but he's definitely not the person who's displayed as the great explorer/researcher that he's made out to be on the show. Trust me if he was posting a response to this, the F bomb would be dropping in every other sentence and he'd probably be banned for the abuse he'd have given you. He's a stereo typical @sshole New Yorker, and darn proud of it. He'll tell you that to your face. I've been out with them on film shoots. The show is nothing like the reality in which it's shot. There's too much hype and BS added to wow the public. You watch the show, and they make it out to be some great dangerous mission or they've uncovered some great mystery, and it's all BS. Those that actually know whats going on can see thru the smoke and mirrors. .
__________________
. No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan |
|
#24
|
||||
|
||||
|
Re: Howe & Howe? What is the Zen of Design?
Kraythe, I gota tell ya: When a boy gets around to start thinkin' ‘bout the spell he's gonna set in the pen, if he gets caught with a car load of liquor, it can be sort of inspirational to his vehicle modification idears.
|
|
#25
|
|||
|
|||
|
Re: Howe & Howe? What is the Zen of Design?
Quote:
Quote:
What I do understand is that as a culture we have become paralyzed by fear and lawyers. Hell they dont even need to win to beat you. Just the menace of them hovering around with briefcases is enough. In alaska they didnt even need to present a rational case to win. They just keep filing BS lawsuits and bankrupting you with legal fees. People yell and scream about manufacturing and innovation going to india and china and cry about its effects but they dont seem to look at the problem but instead want someone to solve it for them and that is the problem itself. 1) Corporate tax rate of 39%. Cant immagine why any company would go somewhere where that rate is 10%. After all dont they know 29% revenue boost is nothing? 2) Poeple getting paid $60 an hour to put a bolt on a car 500 times a day 3) Entrepenuers being terrified of inventing anything because of the circling pack of vultures overhead. 4) Other people strenghthening the vultures by showing fear of anything that might contain a bit of risk. 5) People saying "oh just og buy it from china" instead of doing it themselves. Its really making me ill. But perhaps I have overstayed my welcome here even in a short time. *shrug* Fine I am done venting now. |
![]() |
| Thread Tools | |
| Display Modes | |
|
|