Extreme Design

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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.

In the OSE Model of Change, Extreme Design is driven by moral intelligence and results in Distributed Market Substitution. The concept is an evolution of Extreme Manufacturing.

Tractor Example

  • 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 in engines), about 20' of chain ($200 x4), $150x4 in hydraulic motors. $100x4 for hydraulic pumps. $100x 4 for valves. Sprocket is a big CNC torch cut disk, sandwiched between 3D printed rubber. Bearings are 2 per shaft, or $100 per shaft or $800.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: $2.4k for rubber and $4k for drive. Rest is steel, shafts, bearings. Steel is $28k at $1/lb, but we can do space frame for 1/5 the weight in steel and the rest in concrete for the traction weight - start with 10000 lb frame or 1/3 the weight. Use Space Frame technology. Prototype cost of $16k for 64 hp. Power system is fully scalable at under $4k for 64 hp/28k lb traction. 640 hp would cost $40k for drive + traction, and another 10k for frame, or $50k total. Remote control, so the operator is taken out of the equation. IT gets more attractive once implements are added. Same machine is used as heavy wheel loader. 320 hp would be about $30k.
  • 14 geardown of 520 rpm motor yields about 40 rpm. Wheels are about 20 feed circumference, so 800 fpm is 9 mph.

For best in class Drawbar Pull.

We end up with $100/hp for the power and drive:

  • Power Cost per 64 hp - $2400 total
    • engines for a modular power unit - $1600 + hydraulic pumps - $400 + hydraulics and fittings $400 for 4 engines; frame for Power Cube - $50. Mother Power Cube excluded.
  • Drive Cost - $3400 total for scalability to 640 hp at dual wheel on front and back
    • chain - $800
    • hydraulic motors - $600
    • hydraulic valves for 4 - $400
    • Shafts - 4 - $400
    • Bearings - 8 - $800
    • Tires - serious wheels at $2400 with 3D printing
    • Sprockets - $400
  • Frame cost - not including cab - $2000 consisting of heavy duty rebar Space Frames.


Prototyping the method in 2013: