Transcript Project Poster

THE ULTIMATE TAILGATE
SENIOR DESIGN: P10811
Jonathan Brooks (ME and PM)
Matthew Piatkowski (ME)
Spencer Herendeen (EE)
Objective
The purpose of the Ultimate Tailgate Project is to take the wasted space in a stock pickup truck tailgate and turn it into a useful, completely stocked workbench. The
specifications outlined in this project incorporate a prototype version of this product, with intent to easily convert to a production version at a later date. As a result the
specifications are proof of concept based and do not include regulations for the Department of Transportation (DOT) or the Federal Motor Vehicle Safety Standards
and Regulations (FMVSS). The final product is a fully functioning, aesthetically pleasing tailgate for a 2001 Chevrolet Silverado 2500.
High Level Design
•Meets or exceeds functions and capacities
of stock tailgate
•Provide a flat work surface for the end user
•Provide a main feature clamp
and auxiliary clamp
•Include two storage bins
•Include electrical power
to the tailgate attachment
•Ensuring electrical power is
delivered in a safe and secure manner
that will not damage the current vehicle
•Provide a battery saving function
dependent upon the vehicle’s current state
Detailed Features
Mechanical
Electrical
-Flat work surface capable of supporting
500 lb
-Tailgate surface level with floor of truck bed
-Workmate style clamping device
-Incorporated bar clamp
-Two storage drawers with 50 lb load
capacity each
-Matches up to stock tailgate mounting
points for easy installation
-12 VDC accessory outlet
-Two 120VAC three prong outlets
-Drop of max current to 67%
to save battery when truck is off
-Safety and security shutoff conditions for:
-Vehicle start
-Gear shifting out of park
-Low vehicle battery
-Overload
System Breakdown Hierarchy
Mechanical and Structural Design
The tailgate main structure is constructed from a mild steel square tube structure.
Individual components are MIG welded together to ensure sufficient strength to
withstand a strenuous work environment.
Features incorporated into the tailgate include:
•Black and Decker Workmate style clamping mechanism
•Two removable, modular storage drawers , each with a 50 lb load capacity
•An Auxiliary one-handed bar clamp, mountable to the tailgate frame
•A self actuation mechanism, consisting of two electric motors with gear reduction
to allow for automated raising and lowering of the tailgate
Workmate Style Electrical
Clamp
Housing
Storage
Drawers
Auxiliary Clamp
Pocket
Electrical Power System Design
The tailgate electrical system was implemented using a 2000 W power inverter from the Whistler Group.
This inverter provided the necessary power and safety protections to lead to the decision for the inverter
to not be self-designed. This inverter was thoroughly tested to ensure ideal characteristics and proved at
96% efficiency under a load of 2/3 of the maximum.
The safety lockout conditions were implemented using a set of relays to ensure that the power output was
only active when the vehicle was in park or neutral (when the gear relay was engaged). This provides a
quick switching of approximately 1 s. The set of relays also switches between a lower and higher power
mode. This mode will limit the
output current to 10 A when the
truck is off (relay is not engaged)
and 15 A when the truck is on
(relay is engaged). This current
is limited by a breaker which shuts
off at a nominal 10 A.
The system is also provided with a
LED bank to indicate to the end
user whether the system power is
on, and what current mode the
system is currently in. The
current leading to the LEDs
was limited using an appropriate
valued resistor.
The Team (L-R):
Spencer Herendeen (EE)
Jonathan Brooks (ME and Project Manager)
Matthew Piatkowski (ME)
Acknowledgements:
Special thanks to Chris DeMinco, Dr. Mark McVea, Dr. Chris Hoople, and Mike Hargrave for their
assistance and guidance in the design and implementation of this product