Jack and Stopper for Torque Arm Installation
Left view, front view, and adapter view of the axle jack with stopper
The jack aids the technicians in installing the torque arm into the truck.
During the reassembly of the truck, the technicians encountered challenges lifting and connecting the 550 lbs torque arm to the truck frame. The existing beam-jack setup, capable of holding 2000 lbs, posed safety risks when lifting the heavy torque arm. The jack would often rise too high, causing the beam to bend dangerously. To resolve this, I designed and implemented stoppers on the jack to limit its height, preventing excessive beam bending. After three design iterations, the stoppers effectively enhanced the safety of the torque arm installation process, with weekly monitoring ensuring the continued integrity of the jack, beam, and stoppers.
Background:
During the reassembly of the truck (also called bogie), the technicians must connect the torque arm to the frame of the truck. They have to lift the truck up so the technician can get under and work on the truck.
The torque arm is an arm used to counteract the torque generated by the motor, therefore securing the motor in its place. The torque arm is connected to the truck frame via a rubber grommet (bushing) and a torque link bolt.
Problem:
We currently have a Beam that was retroactively fitted with a jack that is capable of holding up to 2000 lbs. The torque arm's weight is 550 lbs.
When the technician uses a drill to lift up the jack, since the jack moves freely, the top of the jack hits the ceiling of the frame, therefore causing the beam to bend down significantly and poses a safety risk.
Actions:
Designed a set of stoppers to be fitted on the jack that can stop the jack when the jack reaches its desirable heights (to stop the jack from going too high and causes the beam to bend down).
Went through 3 iterations until we found a working solution that does not put too much stress on the rivets.
Results
The 2 sets of stoppers are able to limit the height of the axle so that as the jack goes up, it doesn't bend the beam to past the elastic deformation point.
Increases the safety of the torque arm installation process.