The painting to your right is by the late Dr. Mario Fernandez, whose experience also includes many industrial design efforts, both with us and with others. For example, Mario and his business partner at the time, created Toro's present (and very well known) logo and color scheme that has served the company so well over the years. Samples of some his design work can be found within this website. This graphic was originally included with Mario's permission and left here to honor his memory.
4927 St. Croix Avenue, Golden Valley, MN 55422 | For more information, call (763) 242-7721
Product Development and Equipment Design
The extent of our experience over past years includes something beyond 300++ products or product variations. We would like the opportunity to share this experience with you. We are prepared to put together a design team to provide a solution to virtually any original product development issue or product improvement effort that you can come up with.
"Give me a feature, make sure it doesn't break down, and I'll sell as many as you deliver."
Paraphrase of Mr. Duke Newton, Zahn Equipment Co. of Tampa, Florida, Toro Distributor. Above statement made while educating Toro engineers on the real world of equipment design, concerning a mower on a Tampa golf course fairway. "Feature" means some real or genuine advantage that your product has over all your competition and that the sales force can clearly point to or demonstrate. All else is fluff.
If you would like more information on any of the following items, please click it.
The following eight items (projects) were conducted as direct employee of Toro. If you have owned Toro consumer equipment, you have probably benefited from our design efforts, either as employee, or consulting office to Toro.
PROJECT DESCRIPTIONS
ALGORITHMS, MATHEMATICAL
We are capable of creating mathematical models of most physical, or mechanical/electrical situations. We then convert these into a (almost) real time computer model that allows you to vary the inputs at will. For example, you could vary the ground speed of a vehicle or water speed of a boat. The computer animation would then follow your inputs and could be constructed so as to demonstrate if a boat would porpoise at a particular speed, position of the propeller with respect to the bottom of the boat, the thrust, the wetted surface, the beam, the length, etc.
The program could then vary the above physical characteristics while the boat is moving through the water. In other words, we enable you to "drive" the boat on the computer, follow the action on the screen, and see the results as movable graphics. What's most interesting, is that a test driver of a full size prototype boat can control only the steering wheel and the throttle. With a well done computer algorithm, the test driver would control not just the steering wheel and the throttle. He would also control the hull shape, width, length, center of gravity, engine characteristics, or thrust, propeller position, passenger load and position, and any other characteristic one might choose. This would be a very real interactive design tool for maximizing performance of any particular craft.
AUTOMOTIVE HEATER
Thermodynamic (heat transfer) investigation and analysis of the effect of restrictions in water flow to various automotive heaters for various input water and air conditions. Formal report. www.phillipsandtemro.com
BENCH GRINDER
Electric bench grinder developed from original concept sketches for shape and visual by in-house industrial design group. Performed all mechanism, electrical wiring, internal function for motor and fan position design and planning. Provided full solid model (computer file) and coordinated prototype from fused deposition model. www.blackanddecker.com
BUBBLE SWITCH DESIGN PARAMETERS
This project consisted constructing mathematical models of a number of typical bubble switch configurations. One of our conclusions was that the sharp edge where the bubble met the flat surface was causing very high (destructive) stresses in the PC laminate material at that point. Also, we were able to determine that the problem was worse or most aggravated for the thicker materials.
CD PRINTING MECHANISM DESIGN AND/OR REVIEW
Paper analysis of system for fabrication of compact disk printing system. Developed concept(s) for cost reduction and streamlining of system and reduction of number of parts. A variety of options were looked at. Overall effort resulted in about 25% cost reduction of the basic system. We believe other, more radical changes will amount to even greater cost reductions with an overall increase in performance. www.rimage.com
CHAIR WALKER
This effort consisted of working with a 55 year old woman who had been crippled since she was 15. It was then that her father built her a unit that allowed her to get about with a walker that also served as a chair. We were approached because her 40 year old unit just plain wore out. The unit we provide allowed her to carry her radio, her knitting, magazines and newspapers. We also provided hand brakes for the wheels to allow her to support herself from it in a stationary mode.
CHEESE MIXING DEVICES
Designed and developed full (6-unit) line of cheese mixing devices (could be used for mixing most any product) for essentially breaking up clumps of product and mixing various components.
COAL AUGER TRANSMISSION
Design, coordination and construction of variations of coal auger driving transmissions (client conceptions) including a complete formal load analysis of all components. (Max capacity 25,000-ft. lbs. - very heavy duty.) Formal report submitted. (United States Bureau of Mines)
COMPRESSION RELEASE
System for two cycle engine compression release. Automatic compression release actuation upon pulling on starter rope. www.toro.com
ECG GROUNDING ELECTRODE CLAMP
Design and analysis for ECG grounding electrode clamp for use with ECG heart monitoring equipment. This was a totally new concept which represents quite an improvement over anything now on the market. Formal report.
AUTOMATIC ASSEMBLY DEVICE
This unit was created to perform the operation of crimping the connectors onto the flexible tab ends of printed circuits in order to eliminate a carpel tunnel problem before it degenerated into a much more serious situation. In addition, it allowed the process speed to be increased by over 100%.
ELECTRIC CAR POLISHER
Electric car polishing device for major manufacturer. Prototype used as model for Asian production. This project amounted to the design, fabrication of multiple prototypes, preliminary testing of prototypes, and creation of formal drawings. Completed unit was boxed, and shipped to client. www.blackanddecker.com
ENTERAL DELIVERY SYSTEM
Research effort to come up with various optional methods to pump medicinal or nutritional fluids into patient during various hospitalization situations. Involved review of existing systems, brainstorming of optional systems, and presentation of best options to client (Sandoz Nutrition). www.sandoz.com
FAIRWAY MOWER VIRTUAL PIVOT
This concept was originated exclusively by Mr. Berner of this office. It consisted of a couple pairs of pivoting links which, in turn, created a "virtual pull point" at any desired location. The virtual pull point could even be located below the surface of the ground when the cutting unit was generally level. This configuration reduced or eliminated cutting unit "bobbing" - a visible "ripple" over the cut grass surface. We created a computer animation that allowed the linkage to be pre-calculated and tested prior to fabrication. www.toro.com
FLYING HEAD ACTUATOR
Flying head actuator for simultaneous writing of information on stacked multiple computer discs - complete system concept and design. Devised system to allow individual or simultaneous actuation. System was ultimately incorporated into the disk quality assurance system at IBM's Rochester facility. (IBM Rochester) www.ibm.com
FOLDING HANDRAIL FOR ELDERLY AND HANDICAPPED
As part of a study involving the negotiation of stairways for the elderly and handicapped, a concept was further developed for assisting the individuals to more safely climb up or down stairs. The device essentially amounts to a walker which is affixed to one side of a stairwell and makes it possible to secure one's position all the way up and all the way down a stairway so as to avoid the head-over-heel fall. This is presently installed in about 50 - 55 homes around the Twin Cities metropolitan area. As result of this work, and a couple of other projects, we have gained considerable expertise in the whole area of assistive technology related to safely moving people. We are also looking to license the involved patents to an interested manufacturer. U.S. Government
FOOD DELIVERY CART - HOSPITAL
This effort came about as result of a review of the food delivery system at one of the local hospitals (HCMC). The object was to see if we could come up with a better system for hooking individual food carts onto an overhead monorail that was already in place. The existing system required a combination of high strength and agility to hook the carts on to the overhead rail. We came up with a system for accomplishing this by designing a new food cart with the mechanism for hooking built into the roof. The initial lift force was applied close to the center of gravity of the cart. Simultaneously, the lifting hooks were secured by a snap in (bayonet) lock. We built a quarter scale model unit that allowed us to work out bugs and demonstrate the concept perfectly. www.hcmc.org
GASOLINE CONTAINER WITH BUILT IN PUMP
Design for a gasoline container with a built in hand pump system. This included complete design plus drawings and production cost estimate for the optimal configuration. This included blow molded parts and pump components. www.j-markproducts.com
GOLF CLUB DRIVER HEAD DESIGN
This project consisted of taking client's idea for a golf club driver head configuration, constructing appropriate sketches and drawing(s), prototyping it and finally constructing a set of metal heads for trying out. The process was then repeated for three or four optional configurations. Private Investor
HARD ROCK BIT TESTING MACHINE
Design and supervision of construction of a hard rock bit testing machine. This was used for testing of mining bits by the United States Bureau of Mines. This involved extremely high forces. (United States Bureau of Mines)
HEAVY DUTY AUTOMOBILE JACK
Concept design to working prototype of simple unit to lift 1/2 of a vehicle for rotating tires, etc. Including stress analysis. www.j-markproducts.com
HEDGE TRIMMERS
Developed largest Black & Decker hedge trimmer as extension of the original line. Provided complete line maintenance and production support for four other units of the line.
HIGH SPEED CLUTCH/BRAKE
Analysis and design recommendations for high-speed clutch/brake system design. This included analysis of the problem(s) associated with brake component failure before clutch component failure - an unsafe condition. This particular design study involved the comparison of the capability of the brake system with the capability of the clutch system by way of a Weibull analysis. Report. www.toro.com
JOGGING BUGGY REVIEW AND DESIGN
Initial project involved review of problems concerning Taiwan production of jogging buggies. Participated in discussion with the manufacturer. Later on worked with developing device for attachment of buggy to a bicycle (patented). TRI Industries, Edina MN
LAWN AND GARDEN ELECTRIC APPLIANCES
This was work performed as group leader of eight people employed by Black & Decker. www.blackanddecker.com
GARDEN CULTIVATOR
Developed garden cultivator based upon patent by German inventor which involved use of counter-rotating tines to both cultivate and propel unit in a variety of soil conditions. (Black & Decker).
SIDEWALK EDGER(s)
Developed largest of Black and Decker's sidewalk edgers for edging and trimming in various yard situations. Provided full line maintenance for four other lines.
HEDGE TRIMMERS
Created largest Black & Decker hedge trimmer as extension of the original line. Provided complete line maintenance and production support for four other units of the line.
STRING TRIMMERS
The original Black & Decker string trimmer was created through a couple of people in my group. In this capacity, and because we were the first company to seek U.L. approval for string trimmers, I was also heavily involved in writing the first U.L. specification for string trimmers.
LOUVERS NON-FREEZING
This concept was developed, prototyped and demonstrated in response to the need to prevent louvers for sugar beet barns from freezing up in Minnesota's cold winters. Our concept worked beautifully. Subsequently we became aware that this was also a problem with turkey barns. However, in this case, multiple thousands of turkeys could be lost.
MINNOW DISPENSING SYSTEM
Review of design for a coin operated minnow dispensing system. Major problem was the minnows did not seem to last as long as they should. We identified a problem with the material in one of the components the minnows were exposed to. Also recommended improved aeration system. Part list and cost estimates were also constructed. Private Investor
PRODUCTION DESIGN FOR RIGHT ANGLE REDUCER
Complete design and analysis for high volume production of right angle gear reducer assembly. Report included analysis of AGMA ratings and recommendations. www.toro.com
PROTOTYPE SHOP
Organized Black & Decker's original prototype shop dedicated exclusively for use of the Lawn and Garden group. The object was to allow engineers and designers to construct very rough demonstration type models of concepts. This was to compensate for the extreme difficulty of obtaining that type of support from the main model shop and its competing demands. Partly as result of this, the Lawn and Garden group became one of the top performers (the top?) within the B&D engineering operation. www.blackanddecker.com
PROJECT RETURN ON INVESTMENT ANALYSIS
This was a computerized system for inclusion of all the company's engineering projects into an overall analysis of their combined return on investment. This was necessary because costs assigned to various programs were regularly based upon whimsical figures rather than on factual data. In addition, specific engineers recognized that, due to erroneous tax treatment, new product programs were being unfairly compared to alternative investments. This effort had the effect of putting cost estimates on a more legitimate, professional, footing. (Toro) www.toro.com
RIDING LAWN MOWER
(Project Engineer) Originator of Toro's first successful rear engine riding lawn mower. The vehicle we developed along with the bagging system was essentially the first prototype for subsequent consumer riding lawn mower that became No.1 with Consumer Reports. We originally started out with a friction drive system of our own design. That was later replaced by a standard (purchased) transmission. The cutting deck, deck drive, deck lift system, frame, and grass bagging system, were all worked out on this prototype. Excellent follow-up work, by others, followed with the result of Toro's top entry into the rear engine rider market.
SKY LIGHT ACTUATION AND CONTROL MECHANISM
We developed a control for a window operator to control incremental movement of a window. The control moved the window to an open or closed position. A system was set up for determining when multiple motor drives moved predetermined distance. This was set up to make sure that if one motor outran the others by a small amount, it would stop and wait for the rest. Once all the rest caught up, they would stop and wait till the slowest motor caught up. Then they would all proceed. The process would then repeat. However, the total increment was so small that the overall motion appeared to be very smooth. Truth Hardware www.truth.com
SNOW THROWER - SINGLE STAGE ELECTRIC
Designed and developed single prototype of single staged electric snow thrower based upon utilizing the remarkable low speed lugging power of the universal electric motor. Proprietary experimental.
SNOW THROWER RESEARCH PROJECT
(Asst. Project Engineer - as Toro employee) Worked with senior level research engineer on development of approximately twelve or fourteen different variations of prototype snow throwers. The object was to investigate various concepts and settle on one to develop into a line of snow throwers. The most promising of these units were tested on Mount Revelstoke in British Columbia. Unit concept referred to as the "Snow Mill", for its ability to "mill" the hard packed snow off a driveway surface, came out of this effort. A series of reports, logs, and notes concerning all these variations were completed and left with the company patent attorney's office. In good part, as result of this program and subsequent snow equipment work (including creation of the original version of Toro's current Power Curve snow thrower) Toro came to dominate the United States snow market.
STRING TRIMMERS
Developed original Black & Decker string trimmer, through a couple of people in my group. In this capacity, and because we were the first company to seek U.L. approval for string trimmers, I was also heavily involved in writing the first U.L. specification for string trimmers. It was submitted through cooperation with B&D safety specialist and long time U.L. Board member.
RESEARCH ON TORO'S SNOW PUP SINGLE STAGE SNOW THROWER
(Asst. Project Engineer) Work included experimentation with various paddle/rotor materials and options. Final configuration including rubber paddles and means for attaching to rotor evolved from this work.
TWO STAGE SNOW THROWER PILOT DESIGN PROGRAM
(Project Engineer) Developed the "Snow Mill" concept into a two-stage snow thrower pilot unit which ultimately became Toro's entry into the two-stage market. Its most unique characteristic was ability to survive a two-by-four piece of pine jammed into the front rotors without damage to the machine or shearing a key. Internal company audit concluded the pilot unit's field acceptance and performance was excellent. However, field problems and fabrication issues just about killed the concept. This was due mainly to Toro production's inability (at that time) to produce a consumer product much more complicated than a lawn mower in any significant volume. The next step was to expand the pilot concept into a full three-unit line of two-stage snow throwers.
ULTRASOUND SUPPORT ARM
We were asked by the ARIC study group (Atherosclerosis Risk in Communities) to develop a mechanism that would eliminate the serious discomfort felt in the arms of the technician operating the ultrasound device after a full shift of lifting and holding the sensor. Multiples of these were designed and made for North Memorial Hospital and a North Carolina hospital. One of the additional benefits of this device was that it held the ultrasound transducer so still that it cut the number of photos from 4 or 5 per view, to 1 or two and cut the time in half for a typical set of procedures. North Memorial Hospital, Robbinsdale, MN www.northmemorial.com
VACUUM CLEANER FUNCTIONAL REDESIGN
Developed and constructed two prototypes of vacuum cleaners according to results of a study we conducted to review the production designs. At least two of our major design recommendations were ultimately included in production units. (Kirby) www.kirby.com
VARIABLE SPEED TRANSMISSION
Analysis and design commentary of infinitely variable speed transmission. Complete study of all components of drive including AGMA gear ratings. Formal report. www.polaris.com
VEHICLE TRANSMISSIONS
We have experience in the original design and analysis of a variety of different vehicle transmissions. These include geared three speed transmissions, transaxles using bevel gear differentials, transaxles with spur gear differential systems, golf cars with snowmobile type variable speed transmissions, and friction drive systems (three or four different). www.toro.com
VENDING MACHINE NOISE CONTROL
Investigation and recommendation for modification to cabinet for ice drink (slush) machine to achieve sound reduction. The object was to reduce the sound level to such level as to allow normal conversation to take place in the near vicinity to it. This was handily achieved by a series of changes to the materials and closure of gaps. Another interesting point here was that we liberally applied techniques learned in silencing riding lawn mowers and hand held appliances. www.cornelius.com
WIND TURBINE
Preliminary studies, design, and drawings and prototype construction for roof-mounted wind turbine (augmented horizontal Darius). This effort was an investigation of the possibility of using either man made (buildings etc.) or natural structures such as low hills, tree lines etc. to augment the flow of air into a wind energy device. The results of this effort look quite promising, especially in the northern climates if the power is used to directly operate heating devices. Proprietary
WINDOW BALANCE SYSTEM
Window balance spring analysis and selection system for a variety of window weights and side drag situations. Developed formula for correctly sizing and optimizing spring balance system for double hung windows. Formal report. www.intekplastics.com
WINDOW FRAME REDESIGN
Redesign and recommendation for a window frame system for apartment building windows which would reduce the problem of young children pushing out the screen and falling through. Redesign based on absorption of running child's kinetic energy. We were able to identify and test at least four separate systems that met or exceeded this goal.
The following Toro snow projects were conducted as direct employee(s) of Toro. If you have owned Toro consumer equipment, you have probably benefited from our design efforts, either as employee, or as consulting office to Toro. This is particularly true if you own a Toro 2-stage snow thrower, riding lawn mower bagging system that allows backing up to the pile and dumping grass without getting off the machine, or Toro's Power Curve single stage snow thrower. www.toro.com
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APPLICATIONS RESEARCH, INC. | 4927 St. Croix Avenue, Golden Valley, MN 55422 | For more information, call (763) 242-7721