Extreme Design

2023 Definition of Extreme Design

Extreme Design - problemsolving based on conceptualizing problems in their ludicrous limit - ie, a design which would obviously outperform, but is usually so simple that it is not considered as people seek more expensive, sophisticated solutions. The challenge is to make the ludicrous solution feasible. When accomplished, the cost is 10x lower, while maintaining OSE Spec.

Mundane Examples

• Geardown of extremely high torque wheel drive (7k lb traction force)- 3D printed wheel. Chain drives wheel near outer diameter. This is all done using chain at $10/ft [1] and hydraulic motors at $10/hp. 5:1 safety factor for chain. [2]. Even with single chain and 4 wheels - we have 28k lb drawbar bull (coefficient of traction = 1) for $400 in chain, $600 in hydraulic motors, and for Engines, we have $25/hp in increments of 16 hp. 40 of these would be required for 640 hp. Standard bank is 6 of these for around 100 hp, at $2500. 640 hp is $16k.
  • Useful logical scale is 1 engine to one hydraulic motor. Each motor, with chain at 4" to 56" diameter: 2000 in lb is 500 in lb at 4", geardown of 14x gets us to the 7000 lb pull of the chain.
  • MVP for this system is heavy on the rubber and steel, which gets us to 28,000 lb drawbar pull for a minimum of 64 hp ($1600), about 20' of chain ($200 x4), $150x4 in hydraulic motors. $100x4 for hydraulic pumps. Sprocket is a big CNC torch cut disk, sandwiched between 3D printed rubber. Bearings are 2 per shaft, or $100 per shaft or $400.For rubber, count on 500 lb for a large tire, produced with TPU or TPO 3D printing filament. TPU is $1.25/lb in scrap. $600 per tire, 15000 load rating. Total: $3400+$2400 in tires. Rest is steel, shafts, bearings. Steel is $28k at $1/lb. Prototype cost of

For best in class Drawbar Pull.

About

Prototyping the method in 2013:

edit