ANDREW FLYNN Product Design Engineer Portfolio 2015
coroflot.com/andrewflynn
HALO
Mobile Point of Sale
Project Overview NCR HALO is a mobile point of sale device designed while working for the industrial design and engineering team at NCR. HALO is a unique, new and multifunctional approach to point of sale devices capable of high security EMV compliant chip and pin functions while maintaining a small and compact form factor. The design implements a range of the latest payment technologies as well as future proofing with advanced palm vein biometric identification.
Project stats: Time period: 4 months Members:
Individual project
Location:
NCR Dundee
RESEARCH AND INSIGHTS Stagnant Market Conducting market research quickly identified an opportunity for a unique and innovative design to compete with existing mobile point of sale devices. Current products provide similar functionality in a form factor which makes it hard to distinguish one brand from another.
Multiple Paymet Methods It became clear through user research that a payments device should revolve around user facilitation. This is due to the rapidly increasing number of ways to pay for things. Making the device multifunctional in terms of payments became a requirement of the project.
ADDITIONAL INSIGHTS
Time Sheets
Employee Identification
In-store communication
Members of staff across various sectors including retail and hospitality are required to either manually fill out time sheets or carry a card used to swipe in and out of work.
Shoppers often highlighted the difficulty of locating the right members of staff to deal with specific needs, indicating name tags are often ineffective.
Members of staff are often required to carry or wear radio sets used for in-store communication. These are inconvenient to use and add additional cost for employers.
CONCEPT GENERATION Sketch Development A series of concepts were generated driven by the research and insights gathered in the first phase of the project. A mix of flat paper sketching, hand rendering, quick CAD and adobe creative suite were used to create a range of concepts. The initial concepts explored different aesthetic approaches as well as possible features and functionality. Initial concepts were reviewed and ranked according to how they met the requirements set out by the research.
Defining Functionality Adobe illustrator was used to quickly generate user defined storyboards. This helped determine how different concepts might be used within different environments. Scan bar code
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CONCEPT DEVELOPMENT
Mock-up Models
Defining Components Having chosen a design direction and defined product functionality, a ground up design approach was adopted to ensure an accurate and achievable product was created. Components were sourced and critical dimensions gathered in order to generate accurate tolerance stacks. This helped to quickly define overall dimensions for the product.
Screen Cover
E-Ink screen Verify
Plastic top
Verify
PCB
PCB
PCB
Battery Battery
Palm Vein Sensor
Keyboard Battery
Battery
Induction Coil
Card slot
Camera
Plastic base
A series of models were created throughout the project to test size and usability of the product. Models were created from a mix of card board, foam and 3D printing.
WEARABLE STAFF ID Quickly Locate The Correct Member of Staff HALO utilises two main methods of user feedback. The first is a multicoloured LED ring used to give primary feedback and communication. The LED ring can be used by retailers by assigning different members of staff (or department) a different colour. When worn on a lanyard, customers can quickly identify who they are looking for. The E-ink display can then display a welcome message or name used to engage the customer.
Shops and restaurants can print off an â&#x20AC;&#x153;Employee Keyâ&#x20AC;? used by customers to identify what each colour displayed on HALO refers to.
ADDING VALUE Streamlining Functions HALO has an inbuilt speaker and microphone permitting instore communication between members of staff (eliminating the need for additional radio hand sets). A camera module in the base is capable of scanning bar codes or promotional vouchers eliminating the need for a separate scanner.
CHIP AND PIN Select Payment Method
Enter Pin
A mechanical scroll wheel is used to navigate the E-ink display and a touch sensitive button in the center of the screen is used to select. A card reader in the base of the device allows users to insert a chip card.
A unique pin entry method was devised for the compact, round form factor. This was developed with NCRâ&#x20AC;&#x2122;s accessibility team to ensure users with impaired sight could use the product. Similar to entering digits into a traditional safe, users use the scroll wheel to enter digits one at a time. The LED ring lights up in quadrants as the pin is entered. Tactile markings on the scroll wheel and top face allow for accessibility.
CONTACTLESS PAY
Card or Mobile HALO facilitates NFC contactless payments allowing it to be used with both contactless cards as well as mobile payment methods such as Apple Pay. Combining the mobile nature of HALO with fast payment methods such as Apple Pay allow for high speed checkouts. Once paid, receipts can be emailed to customers straight from the device or printed via an internet connected printer at the till.
BIOMETRIC KEY A New Approach to Payments Palm Vein authentication was proposed as a third, future payment method. The sensor, developed by Fijitsu, was incorporated into the design of HALO. Similar to a finger print, the sensor would use the palm vein pattern to look up and verify an account all in one swift, non contact hand gesture. The infared camera sits hidden under the transparent touch sensor. The non contact nature of palm vein is well suited to a publicly used product, helping prevent the spread of germs.
Transparent touch sensor
Fijitsu Palm Vein Sensor
CLOCK ON, CLOCK OFF A Smart Incentive During the concept development phase of the project a solution was developed to solve three problems in one. The challenges were: • A suitable place to store and charge the products. • Provide a simple means of tracking employee hours. • Prevent staff from leaving the store with a secure payments device. A hanger charging dock was developed for HALO which consists of a coat hanger style rack and an induction charging rail. An a-symmetric magnet inside the base of HALO allows it to snap to the charging rail. Using NFC the device clocks employee hours at the beginning and end of a shift. This would ensure staff return the product at the end of the day.
DESIGN DETAIL AND ANALYSIS Navigation wheel
Contruction Overview
Light Guide
Pressure Sensor
The transparent snap fit cover contains a 45° bounce line which guides the light being emitted from the perpendicularly mounted LEDs.
Pressure sensors sit between the bosses of the product. These determine whether the product is being tampered with.
Below is an exploded view containing all of the major components which contribute to HALOâ&#x20AC;&#x2122;s functionality. Components could be added or subtracted depending on cost of the final device.
Snap fit cover E-ink Display
Touch input
The wheel is mechanically held between the top and bottom of the enclosure. A potentiometer converts rotation to electronic control.
Enclosure top
Scroll wheel
PCB Assembly
Lithium Ion Battery Card reader Audio input
Vibration motor
Magnet
Enclosure base
Silicone ring
Mechanical Check To ensure the product was robust a series of finite element analysis simulations were carried out. The polycarbonate casing was subject to a series of point loads (imitating the force of a finger) to ensure the material did not yield at a range of typical pushing forces.
HALO STAND The HALO stand was developed as a means to provide a fixed point of sale alternative. The stand incorporates a steel ring which is used with the magnet inside the base of HALO to fix the product to the stand. The power cable, routed through the metal frame, runs to an inductive charging coil used to charge the product. A hole in the resting cup allows the camera on HALO to scan items in the area behind the stand. The metal frame is also free to rotate allowing the customer to face either the HALO display or card slot when required.
NOVA
Unimpeded Travel
Project Overview My masters project was carried out in collaboration with Airbus, Bauhaus Luftfahrt, British Airways and Siemens. This project explored how to improve the airport experience for passengers, airport operators and airlines with a focus on the potential applications for wearable technology. This project combined disciplines of product design, system design and design engineering.
Project stats: Time period: 8 months Members:
Individual project
Locations:
Glasgow/Munich/Toulouse
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TRAVEL MADE SIMPLE Nova Overview
Modular strap
Nova
Nova is a wearable product which streamlines airport transit for passengersâ&#x20AC;&#x2122; by eliminating the need for repetitive manual document checks. Passengers can pass through checkpoints instantaneously, dramatically cutting the airport transit time at departure, connections and arrivals. Airlines can utilise Nova by tracking passengers through an airport terminal, improving aircraft scheduling and reducing delays. Passengers also benefit from this by receiving key travel updates direct from the airline.
Fastener
Biometric identity
Modular design
Indoor positioning
One travel document
Travel updates
Enables seamless travel
1. Translucent silicone cover 2. Flexible TPU casing (upper) 3. RGB LED matrix
Technical Details Nova consists of a series of lower power electronic components which together make up its function. The product casing houses an internal electronic sub assembly which contains a reflectance pulse sensor, Wi-Fi tranceiver, Lithiumion battery and an LED matrix display.
4. Flexible TPU casing (lower) 5. Removable silicone strap
6. Pulse sensor + PCB 7. LI Battery
IMPEDED TRAVEL CHAIN Airport Overview Airport transit is a slow and time consuming process for passengers. This is due to a series of bottlenecks caused by a multitude of repetitive passenger checkpoints. The volatile nature of airport queues leads to unpredictable waiting times which, has lead airlines to enforce a minimum pre-departure arrival time for passengers. On average, a passenger will spend one third their travel time in airports. With the number of passengers constantly increasing this disjointed and dated system is working at capacity and requires a solution which is both cost effective and with minimal infrastructural change.
Check in
Security access
Border Control
Boarding
Connection check
Travel document
Landing Card
Boarding
PASSPORT Travel document
Landing Card
Flight 2KJ
PASSPORT
Boarding Pass
Landing Card
Flight 2KJ
Travel document
Boarding Pass
PASSPORT
Flight 2KJ
Travel document
Boarding Pass
PASSPORT
Flight 2KJ
Landing Card
Boarding Pass
Travel document
Flight 2KJ
PASSPORT
Boarding Pass
Flight 2KJ
Travel document
Flight 2KJ
PASSPORT
Boarding Pass
Destination
Boarding Pass
Enter Airport
Border Control
What users want
What If?
Time spent interviewing and observing passengers lead to a range of key insights which were used to develop Nova. Many passengers sought a system whereby they could flow through the airport seamlessly. Attempts have been made to create an unimpeded travel process, however current concepts all require time to process passengers when they reach a checkpoint, which leads to bottlenecks.
Passengers were able to pass through checkpoints instantly without being stopped, creating a truly free flowing airport.
Pre-checked passengers
Travel Documents
SINGLE PASSENGER TOKEN
It was clear from studying the airport passenger experience that the multitude of paper travel documents is a cause of stress for passengers. A common problem which was highlighted by many travellers was that having to constantly remove passports and boarding passes increased the risk of losing them. Furthermore, extra documentation such as landing cards are often a cause of confusion due to a lack of consistency with how and when they are used. An opportunity was identified to combine this array of documents into a digital format stored on one wearable device, attached to the passenger throughout the journey.
Feedback from Bauhaus Luftfahrt suggested this system could be extended to combine tickets and documentation from every mode of travel into one multi-modal travel key of the future.
Material
Passengers no longer need to carry a stack of paper documents each time they travel, worrying whether or not they have lost their passport. Nova is an all in one travel product which helps lighten the load and ease the mind.
Travel products, such as passports, are designed for use for up to ten years. It was important to select a material which was not only suitable for the design but cost effective and durable. Using Cambridge Engineering Selector, TPU was chosen as the main material for the product casing. This material is flexible, cheap and very long lasting.
UNIMPEDED TRAVEL Enter the airport
Confirm and store identity on Nova
Pass Instantly Nova uses a Wi-Fi transceiver to communicate with the world around it. A valid passenger identity stored on Nova means there is no processing time required at a checkpoint. Nova wirelessly communicates with the gate when it comes within a determined radius, transmitting the valid passenger ID. The gates open on approach permitting a seamless walk through experience.
Seamless Travel The key challenge was to design a product or system which allows passengers to pass through the airport unimpeded. A wearable product was developed which was able to store a passengers identity and detect when it was being worn. In doing so, the passengers identity would remain valid so long as the product remained attached to the user. After entering the airport, passengers would carry out an initial identity check at a self service kiosk. Using the kiosk, Nova would be tagged with the validated passenger identity, storing it until taken off. So long as the device remains attached, passengers are able to pass through identity and travel document checkpoints without having to queue, dramatically increasing the speed of the user journey.
Destination Check in
Security access
Border Control
Functional Prototype A functional prototype was developed towards the end of the project. This proof of concept model is able to detect when it has been
Enter Airport
attached to the user, transmitting the sensor data to a receiver where it displays which state the device is in; being worn or not being worn. This functionality determines whether the passenger details remain valid.
Boarding
Border control
TAMPER DETECTION Key Challenge After being stored on Nova, a passengers identity will remain valid so long as Nova remains attached to the user. This is the key premise behind the design of Nova. To achieve this functionality the product required a means of tamper detection. A range of initial concepts and functional prototypes were created which were able to detect when they were either on, or off, the user. A range of sensors were tested using an Arduino to carry out different commands. The key to this design was to ensure the detection method was reliable and most importantly secure and tamper proof.
After storing the passenger identity, Nova ensures it is connected by means of a pulse sensor. Light is used to measure the changing volume of blood creating a PPG waveform. Software detects the pulse and knows it is being worn by the user as a result. If no pulse is detected the device has been taken off, rendering the identity invalid.
Heartbeat as a travel key Sensor Separation
Light propagation
Photon diffusion theory used to calculate the sensor separation required for a maximum transmission depth of light of 2mm in tissue.
Beer-Lambert law was used to calculate which wavelength of light is most suitable for pulse detection. Green light at 500nm is absorbed easily by hemoglobin, a green LED was chosen for the design.
z0 (x) =
2 1⎡ 2 ⎡⎣ x 2 + (d − x)2 ⎤⎦ + 32x 2 ( d − x ) − x 2 −(d − x)2 ⎤ ⎢ ⎥⎦ 8⎣
log10
Light transmission vs wavelength!
I0 = ε lc I
100 90 80
z
max 0
d=
2d = 4 4 × 0.002 2
d = 5.65 × 10 −3 m
LED
PD mm
5.65
I log10 0 = 0.755 I I = 10 −0.755 I0 = 18%
70
Light transmitted %
Feedback showed optical pulse sensing was the least invasive and most reliable option of detection. Pulse detection is very difficult to imitate unlike other biometrics like a finger print. A reflectance pulse sensor was used with arduino to test the concept. PPG singals also showed promising signs for use as a form of biometric identification. Pictured in the trace below are three different pulse sets recorded from three individuals. By simple means of inspection it is clear to see each trace produced is unique.
60 50 Oxyhemoglobin 40 30 20 10 0
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MODULAR DESIGN Sensor placement
British Airways
The reflectance pulse sensor was used along with Processing software to determine body locations a pulse can be measured from. This was used to determine where the product could be worn. Pulse can be measured anywhere there is capillary tissue close to the surface.
Early in the project a partnership with British Airways was formed. This lead to a tour of Heathrow Terminal 5 as well as the BA headquarters and engineering department. Nova was presented at BA to a range of employees from different departments. This produced a range of valuable feedback and insights which influenced the design.
Inclusive Design One of the key points British Airways raised was that the product should not be limited to one body location as it could limit the size of user group. BA suggested making the product modular allowing it to be worn at different body locations.
Product placement Having previously determined body locations capable of measuring pulse, feedback from BA was considered and a modular design was developed. A range of visuals and 3D models were used to develop the design of the module.
User feedback showed the most convenient placement of the product was the wrist.
PERSONAL TRAVEL GUIDE Travel information
Design Opportunity As a wearable device, Nova provides the perfect platform for real time travel updates direct to the passenger. A series of interface tests were carried out with users. Power consumption was a key factor and as a result an LED matrix display was selected for its versatility and low energy useage.
Observational research showed that travel updates, in their current form, confuse passengers. At several points throughout the airport journey the same phenomenon occurs: passengers, standing staring, blankly at an information heavy screen. Trying to locate the relevant travel information is not only stressful but slows down the travel process.
Passenger attaches Nova and LED strips glow yellow to indicate device is attached but is waiting for ID verification. The matrix displays a pulse wave indicating the Nova is connected.
After verifying passenger identity the LED rows glow green. Nova then displays the next mode of travel the passenger is due to take that day.
Battery
Wi-Fi
LED
MCU
AFE
PD
LED array
Using the one button on the side of Nova, users can scroll through the different interfaces. The button is held on to turn the device on and off. Time until next departure is displayed here.
LED matrix
In the airport Nova can be used to display key travel updates like gate number. If a passenger is unsure of directions Nova can be used to guide the passenger using prompts of near by landmarks.
TRACKING The Problem
the passenger or to go without them. This would save airlines time and money while reducing delays for other passengers.
Airside
Landside
Delayed or missing passengers cost the airline industry a total of $600,000,000 per year due to the extortionate costs of grounding fees at airports. At present, airlines only know if a delayed passenger is either landside or airside (as seen in figure 2c). With no way of knowing exactly where a passenger is within the terminal building, it is impossible to schedule departures accurately. If airlines were to know a passenger’s location they could then work out whether it was worth waiting on
Solution - Beacon - Signal range
Indoor Positioning System Passenger tracking is enabled for airlines and airports by using a series of indoor beacons which measure the received signal strength from near by Nova devices.
- Passenger
Several experiments were carried out to determine a method of tracking. Testing showed received signal strength indication (RSSI) varies logarythmically with distance. Using a transmitter and set of receivers a fully functional proximity based indoor positioning system was created.
- Gate Receiver
Internal Product Structure
Transmitter
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RSSI vs Distance 70
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LI Battery
Wi-Fi tranceiver
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A FAMILY OF PRODUCTS
Target Market Interviewing and observing a range of different passengers at Heathrow and Glasgow airports helped define the target market for Nova. Nova would be sold by airlines to passengers looking to improve their passenger experience and streamline the journey. Therefore, the target market is those who are willing to pay for the added benefits Nova can provide. User research showed the most likely users would be families and those traveling on business. Research showed that many frequent flyers travelling on busisness do not fly business class and that the airprot was often the most stressful part of the trip. Nova offers a solution which dramatically improves the airport experience but for a fraction of the price of a business class ticket.
Family Friendly Easy ID:
User Acceptance Tests It was important to gain feedback from some of the key traveller types to determine if they would mind wearing Nova throughout the entire trip. Two separate users were given the product to take with them on a trip. Feedback stated neither passenger found wearing the product an inconvenience and would be happy to wear it given the added benefits.
Proximity:
Out of range:
DESIGN FOR MANUFACTURE Material selection and moulding Thermoplastic polyurethane was selected for its high yield strength and low Youngâ&#x20AC;&#x2122;s modulus giving the casing its desired flexible properties. A mould flow analysis was carried out to ensure the part could be successfully injection moulded. MATERIAL
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UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH: TOLERANCES: LINEAR: 0.1mm ANGULAR: 0.1mm NAME
DEBUR AND BREAK SHARP EDGES
FINISH:
SIGNATURE
DATE
DO NOT SCALE DRAWING
REVISION
TITLE:
Exploded Isometric
DRAWN CHK'D APPV'D MFG Q.A
Model and assembly A polyurethane adhesive is used to bond the casing together. This allows the case to remain flexible and gives the joint excellent peel resistance. Prototype models were created of the design incorporating the pulse sensor and a moulded silicone strap.
MATERIAL:
WEIGHT:
DWG NO.
SCALE:1.5:1
A3 SHEET 1 OF 1
Fill time
Ease of fill
Sink marks
PLUGGO Self set brief: Improve the Apple â&#x20AC;&#x153;out of wallâ&#x20AC;? experience 3 month
group project
Project overview Pluggo was an extra project carried out during my final year. The project came about over the Christmas period when a course mate and myself were looking to do a short design project before starting the second semester. The project ended was developed throughout our second semester and was shortlisted for the final four in the Deutsche Bank Start Up Award.
Awards:
Award finalist
Available at:
Key Insight The low profile, minimal design of the Apple plug makes it difficult to remove from a UK style socket. This insight was first identified while speaking to a course mates mum about what she finds annoying in her day to day life. After speaking to a range of Apple users, it was confirmed that several people find this to be an issue.
DEVELOPMENT Sketches were used during the initial ideation phase of the project to help explore how a grip product could be added to the plug. It was important to determine the maximum distance the plug could be from the socket while being able to draw power. Simple tests using cardboard showed that 3mm was the maximum separation possible.
A range of different designs and mechanisms were 3D printed and tested with Apple plugs. It was important that the design could be used with all Apple plugs (which vary in shape and size) and therefore different hinge designs were tried and tested.
FINAL PRODUCT Pluggo is a small and portable Apple charger grip which can also act as a small ledge to hold your phone while itâ&#x20AC;&#x2122;s charging. A folding handle provides an easy to use grip when pulling the plug from a socket. When not in use, the handle folds back into the profile of the plug maintaining the low profile and portable design. The final design can be found on Shapeways where it is available to purchase.
BUSINESS VENTURE After finalising the design of Pluggo, it was used as a platform to demonstrate a potential new manufacturing process for low level production. This was pitched as a new business venture which placed in the top four of this years Deutsche Bank Awards. Moulds were created for Pluggo which were then used for casting. This enabled a range of high quality Pluggos to be made at a fraction of the price of 3D printing. This was used to help demonstrate the intended process of injection moulding into 3D printed moulds.
Casting process
Polyurethane Pluggos
Bull Bicycle Lock Project Overview This project was carried out as part of the international Hands Off My Bike NESTA competition. The goal of the project was to design a new type of bike lock that would deter theft. The Bull Bicycle Lock was shortlisted from an international pool of applicants for final testing and judging. This product is still under development.
Key Insights Public bike locking infrastructure is unreliable and often overcrowded. Cyclists carry personal locks as it allows them to lock their bikes virtually anywhere. However, secure bike locks tend to be large, heavy and awkward to carry. As a result, cyclists compromise by buying less secure locks which often leads to theft.
Project Stats: Time period: 1 month Members:
3 group members
Location:
Glasgow
CONCEPT GENERATION Initial testing was carried out on a range of bike locks in order to determine which of the current designs is most secure. A range of locks were purchased and a range of different cutting tools were used to test the strength of each lock. Many of the locks were cut in under 10 seconds with a miniature hack saw or a pair of pliers. The D-Lock and chain lock were the most resilient, however the size and weight of these locks make them impractical to carry. Furthermore, a pair of heavy duty bolt cutters are able to break each of these in under 10 seconds.
Strap lock
Handlebar lock
Spinning core lock
Personal bracket lock
The key challenge was to design a lock which was more portable than current bike locks and more secure. Sketching, prototyping and CAD were used to develop a range of initial concepts. These were then evaluated against a set of criteria determined in the research phase of the project. The integrated handlebar lock was chosen for further design development as it best matched the design criteria.
Prototyping A series of different handlebar concepts were designed and built for users to test. Quick mock ups were used to test different user interactions with the lock in order to evaluate and iterate the design. Video prototyping was also used as means describing the concepts to users who did not have access to a physical prototype.
Storyboarding Using early CAD work, I was able to create storyboards which I used to describe some of the key interactions in more detail. The majority of the CAD was carried out in Solidworks for this project and rendered in Keyshot.
FINAL DESIGN Design Overview
Locking hole
The final design of the Bull Lock consists of a central locking unit and stem clamp and two detachable steel bar ends used to lock the bike. A working prototype was made by heat treating and bending steel tubes and milling the central locking unit. The central unit also has room to mount brakes.
Centre lock
Space to mount brakes
Stem locking clamp
DESIGN DETAIL Central Lock
Locking Mechanism
A central locking mechanism is used to lock the two handlebar ends in place. A key rotates the central locking column by 90 degrees which slots into the grooves of the two bar ends. Centre Lock Centre Centre LockShaft Centre Centre Lock Pin Shaft Centre Pin Shaft Bar End Pin BarBar EndLock Centre Lock Centre Shaft Pin Bar End Bar Lock
Counter-acting Torque It was clear the central locking point would experience large moments while the handlebars were in use. To reduce the risk of failure a flat area was machined onto the bar ends and designed into the central housing. This decreases the forces experienced by the pin.
Material Selection
Rubberised Rubberised Ceramic Rubberised layer Ceramic layer Hardened Ceramic layer Hardened Hardened Rubberised Ceramic layer Hardened Rubber outer layer Cermet Coating Hardened steel outer layer outer layer outer layer steel core steel core steel core outer layer steel core
BarBar EndLock
APPLE DESIGN CHALLENGE
Mechanism overview
AA Battery Door Mechanism Entire project carried out in a time period of one week and then presented at Apple HQ in Cupertino, CA. The project brief was to design a AA battery door mechanism for a hypothetical iPod which uses replaceable batteries. The design uses a push to lock, push to unlock mechanism aiming to reduce the number of parts and overall footprint.
The magnetic pin is designed to follow a recessed path moulded into the plastic battery casing. The pin is constrained horizontally by a slot machined into the aluminium tray. To reduce friction, the pin has a rectangular cross section designed to resist rotational forces. This ensures the pin does not fuse with the aluminium tray as it moves round the one way path. The sprung battery terminal at the base of the casing acts as the ejection mechanism.
How it locks: Magnetic array
Moving Pin
Plastic guide
Battery Tray
The diametrically magnetised neodymium pin is guided through the one way cycle by three stationary magnets. When fully inserted the pin locks and is held by a latch in the moulding. When pressed down a second time the pin is released from the latch and the tray comes free.
PRODUCT ANALYSIS Free Body Diagram An important factor of the design was to determine a spring with the correct spring stiffness. This was done to ensure the ejection mechanism had enough force to overcome the weight and friction of the tray holding the batteries.
Fs > Fr + W
Parameters Fm = 0.85N m tray = 11.53g m battery = 23g μ PC = 0.31 g = 9.81m/s^2
X spring = 3.5mm K spring constant = ?
Fm
N
Frictional Force Fr = μFm Fr = 0.31 x 0.85 Fr = 0.26N
Injection Fill Time Mould flow analysis was used during the design process to ensure the polycarbonate part could be moulded effectively. The simulation was used to ensure an even fill rate and total time to fill. One half of the battery casing is moulded in less than one second.
Ease of Fill The ease of fill helped to determine the correct wall thickness of the PC part. Initial simulations suggested the wall thickness was too thin resulting in high injection pressures. Increasing the wall thickness reduced these pressure levels.
Weight W = (Mt + Mb)g W = (0.01153 + 2 x 0.023) x 9.81 W = 0.56N Fs > Fr + W Fs > 0.26 + 0.56 Fs > 0.82N
Fr
W
Hooke’s Law (linear spring) Fs = -kX
K = -(Fs/X) K = -(0.82/3.5x10^(-3)) K = 234.3 N/m K > 234.3 N/m
Sink Marks Identifying potential sink mark areas helped refine the design of the part. Ensuring a consistent wall thickness throughout the part helped reduce possible deformations. Eliminating deformations was important for the mechanism design.
NCR PORTAL Brief: Design an ATM you would cross the street to use. 3 month
individual project
Project overview This was a three month industry project carried out with ATM manufacturer, NCR. We were tasked with designing an ATM you would want to cross the street to use. This project takes a user centric design approach to improve the experience of using an ATM at night. The project was part of a national competition run by NCR which involved students pitching their final concepts to a panel of judges at the end of the project. Portal, won the NCR Design Competition 2012.
Key Insights ATMs have been made to function 24 hours per day however, they have not been designed to adapt to user needs between day and night time environments. Most ATM users feel uncomfortable using an ATM at night saying the process took too long.
MODEL MAKING Design Overview The development of the NCR Portal involved several 1:1 scale prototypes used to test with users. Taking a user centric design approach helped guide the functionality of the product as well as the aesthetics. Prototypes were created from a mix of vacuum forming, LED lighting and lasercut plastic. A prototype ATM location app was also created.
FINAL DESIGN Portal transforms at night, only providing streamlined cash withdrawals allowing users as quick a transaction time as possible. The lighting system guides users through the transaction process reassuring the user of the streamlined process. The iconic green ring is unique and easily identifiable at night.
THE APP Locate a safe ATM in a safe environment with NCR night APP.
THE HORIZON SYSTEM
The Horizon System was a team project carried out for Airbus to conceptualise a solution to door to door travel in the year 2050. The radical ground and air transport system was recognised internationally and featured in a number of media outlets and exhibtions around the world.
Partners: Featured:
WIG AIRCRAFT
Project Overview This design and visualisation project was carried out for a confidential client proposing a new type of mass transit vehicle for Asia. Working closely with a team of aeronautical engineers, data from CATIA was used as the basis for designing and styling the vehicle using a combination of Alias Automotive and Solidworks.
GROUND HANDLING Detailed analysis was carried out of the current turnaround process and opportunities for improvements identified. A range of vehicle and system designs were created exploring how passengers could dynamically board and deboard an aircraft.
The novel ground handling vehicle was designed to work with any aircraft, however the performance is optimised when used with the new cabin design. The new vehicle also reduces the required GH vehicle count to four. In combination, system analysis showed turnaround times could be reduced by up to 61% and the cabin passenger density increased by 45%.
Articulated Air Bridge
OTHER WORK ProControl Cycling Prosthetic: Utilising additive manufacture for custom fit prosthetic
Water Pump: Working peristaltic pump designed and constructed
Electric Search and Rescue Snowmobile: Mechanical design engineering project in a multidisciplinary team
References
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Impressive! The first word that comes to mind when I think Andrew Flynn. There are many other words to describe him as a Product Design Engineer- all of them equally positive, but the first word is impressive. I met Andrew while teaching at GSA last spring. He was leading a team of talented folks and they presented there solution to global commuting- HORIZON. I was blown away. It was impressive. I was lucky to work with Andrew and help refine his pitch and how he addressed notes and iterated on his presentation and ideas was impressive. HIRE this man! He has everything you need. A fantastic imagination, an understanding of engineering and a sense and compassion for who and what you are designing for. Collaborative and inventive he would be an asset to any project.
Mark Andrews: Director at Pixar
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Andrew was the winner of the 2012 NCR | Scottish Student Design competition. Developed over a six week period his concept was well researched and his design realisation both innovative and beautiful. Andrew’s final presentation was very professional in delivery and his model and supporting visuals were of a very high standard. He set a very high standard for the competition.
Andrew was very focused with his design objectives and knew what and how he wanted to achieve. Through a series of reviews and interactions with industry professionals, Andrew responded well to feedback, taking suggestions on board as well as justifying his design choices professionally. In the time I worked with Andrew, design progression and evolution was always clear and well presented with constant reference to the needs of the specification. A talented Engineer who would be an asset to any design team.
Charlie Rohan: Director, Consumer Experience at NCR Corporation
Stuart Hatch: Project Manager, In-Flight Experience at British Airways
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THANKS FOR VIEWING! More projects can be found at: coroflot.com/andrewflynn