Portfolio_Sachin Bijadi by sachin bijadi

SACHIN BIJADI product design student

sachin.bijadi@gmail.com | 612-532-5852 | Sachin Bijadi

SACHIN BIJADI product design student

sachin.bijadi@gmail.com 612-532-5852 Minneapolis, MN

experience Medical Robotics & Devices Lab: Research Asst. 2013-14, UofM, Minneapolis, MN

education University of Minnesota, Minneapolis, MN College of Science & Engineering MS Mechanical Engg. (w/ Product Design Minor) expected graduation 2014 GPA: 3.75/4.0

Developed SmartLight surgical smart tool concept for trans-venous heart lead extraction using Fiber optic sensing for real-time feedback & imminent error detection. Currently working on design of advanced Silicone robotic 3D printer for biomedical applications.

National Inst. of Technology-Karnataka, India B.Tech Mechanical Engineering graduated 2010 GPA: 8.66/10.0

City Bebe Ltd./UofM: Designer 2012-13, Minneapolis, MN Designed and developed new premium urban stroller concept ‘City Sherpa’; undertook detailed market research, developed business plan; completed subsystem design and system integration and built workslike prototype

Tata Motors Ltd.:Assistant Manager 2011-12, Pune, India (NPI)

affiliations

skills

Managed cross-functional team for development of new X4 passenger vehicle platform; undertook market research & analysis initiatives for special projects; worked on interiors design proposals and ergonomic packaging

2010-11, Pune, India (GET) Undertook separate projects in Sales & marketing, Manufacturing (vehicle assembly) and Process planning (digital manufacturing - tool design and operator ergonomics) through GET rotational program.

NITK Innovation Center: MechE Lead 2009-10, Surathkal, India Project ‘0CTAVE’ - Developed a novel ‘Reverse Printer’ concept for reuse of printed paper; investigated deinking methods, developed and tested deinking mechanisms and built proof-of concept prototype.

awards

interests

Industrial Designers Society of America Product Devlp. & Mngmt Assc. (PDMA) Human Factors & Ergonomics Society Society of Automotive Engineers IEEE (NITK chapter)

2013201320132009 2009

rapid ideation & brainstorming; concept sketching & rendering; SolidWorks, Creo, Adobe CS6, Ansys, Fluent, Catia/Delmia, Siemens PLM, Matlab; model making; design thinking; movie making (directing and editing w/ Sony Vegas); 3D modeling, rendering & animation (3DS Max); project management; consumer research; Microsoft Office; basic German. UofM Departmental Fellowship Kaizen Certificate (Tata Motors) NTSE National Scholar (Govt. of India) 6th Rank, Karnataka State, SSLC exam (Grade 10; 99.99 percentile)

2012 2011 2004-10 2006

music: vocals and guitar; arduino programming; computer gaming; sports: tennis, shuttle badminton, soccer; quiz; movie making: directing, cinematography and editing; human psychology and behavior mapping; writing short stories, articles & commentaries; scuba diving

sachin.bijadi@gmail.com | 612-532-5852 | Sachin Bijadi

an efficient multi-functional lighting solution for rural households The average rural household in developing countries consumes energy in the form of electricity, gas and kerosene, all conventional, and scarce. Given the trend of ever-increasing energy needs how can we harness renewable energy sources to provide an efficient lighting solution independent from scarce conventional sources of energy?

Renewable energy technology can help reduce dependence on electricity and help improve day-to-day lives of rural households that do not have access to electricity Under the Jawaharlal Nehru National Solar Mission (JNNSM) huge impetus has been given to development of sustainable solar power technologies to harness the ample availability of solar power. - teri teriin.org

Despite an ambitious rural electrification program some 400 million Indians lose electricity access during blackouts. Just 52.5% of rural households had access to electricity in 2008 as compared to 93.1% in urban areas. Nearly 35.5% of the Indian population still lives without access to electricity. - The Electricity Acess Database iea.org

There is a marked dependence on conventional energy sources like electricity - most household appliances run on electricity, of which there is tremendous shortage Electricity LPG (Liquefied petroleum gas) Kerosene (& other fossil fuels)

Household energy consumption

OPPORTUNITY: SOLAR POWERED HOUSEHOLD LIGHTING SOLUTIONS • Given the sheer size of the consumer electronics market, there is tremendous potential for large scale production of alternate energy-source products like lamps. • There is a dearth of portable solar lamps with easy-to-use charging systems • There is a need for an efficient design to provide multiple functions to adapt to the requirements of a rural household GOAL: Design a portable multi-functional solar lamp for rural households

INDIVIDUAL COURSE PROJECT ME 411 Integrated Product Development & Prototyping

FALL 2008

Advisor: Dr. S.M.Kulkarni

Target Customer & Usage Profile In order to understand the lighting needs of a rural household, I interviewed rural families in and around Mangalore, India.

Demographics • 41 yrs Male, Married • Wife: Homemaker; 4 kids • Annual income: Rs. 80k

Product

Psychographics

• Solar lamp • Rs. 450

• Extremely hard working • Has studied only till high school, but wants to save enough to send all children to college • Not very tech-savvy, but likes using new technology in farming • Very close with brothers and other family • Traditional thinking mindset

Motivations & Aspirations • Own his own land • Education for all children • Develop village: infrastructure, resources, etc. • Pay off debts

Lifestyle • Active lifestyle – Farming on the fields, walking, tilling, etc. • Participates in local village administration • enjoys watching TV with family in brother’s house when there is power • Visits temples during weekends

Ramanna Farmer

SOLAR LAMP USAGE Weekdays

Weekends

• use as emergency light when power goes off wife uses it in be -tween for cooking in the kitchen • I use it like a torch and take it with me when need to walk to the fields at night or other outdoors work • children use it for doing homework

• There is usually no power on Saturdays, so we use the lamp continuously in the evening • Sunday, there is power all day, so we put it for charging with solar panel on our roof so its ready and fully charged for the next week

What the lamp means to me....

Productography • Looks nice • very heavy and difficult to carry • does not have torch • doesn’t break easily • takes really long time to charge, sometimes doesn’t finish charging by the time electricity goes off in the evening • I wish there were a radio on this so I could listen to music

.....“Status: My friends think ‘He has a fancy foreign lamp’” .....“The children can do their homework even if there is no power…” .....“Without the lamp, we have to use candles, and they get used up very fast!” • Looks nice • Doesn’t get damaged very easily • Can adjust light intensity as required

• Very heavy • Too much time for charging • Solar panel very big & inconvenient

Sachin Bijadi | 612-532-5852 | sachin.bijadi@gmail.com

From the direct customer interviews and Customer needs analysis I found that there was need for a novel compact portable multifunctional solar lamp design

design requirements ergonomics

The ability to carry the lamp around was expressed repeatedly >> A portable lightweight design is required with compact dimensions and ergonomic operation

durability

Farmers take their lamps out to the fields where it has to face the elements. It needs to be rugged, impervious to regular wear and tear and be reliable in operation

multi-functionality

The kids, mother and father all use the lamp for different purposes and the lamp needs to adapt to all their requirements with multiple functions

IDEATION

PRODUCT ARCHITECTURE: MODULAR V/S INTEGRATED

Low-fidelity phase 1 CAD models

product architecture

From the initial concepts the architecture of the product was evaluated in phase 1 before further refinement of concept for phase 2. The initial concept was envisioned to be used in 2 major configurations: 1. Portable mode (Flashlight / Emergency lantern) 2. Room lighting mode (wall-mounted) Keeping the design requirements in mind and the parts of the lamp, a modular architecture is more suitable to allowing multi-functionality for this product concept than an integrated product architecture.

sachin.bijadi@gmail.com | 612-532-5852 | Sachin Bijadi

Components: 1. Flashlight

5. Solar panel

2. Lantern

6. Solar charging unit

3. Main battery unit

7. Handle

4. Auxiliary battery unit

8. Radio unit

Awkward angle of holding flashlight: causes pain & discomfort. It is better to design handle to a more natural angle for power grip posture.

Handle is designed to give a more natural angle at wrist for a secure power grip, with flashlight still pointed in the right direction.

Ergonomics & Form exploration

Thumb grip

Notch on underside of handle provides support for index finger while holding the handle

Handle profile and c/s were tested for max. comfort through wrap-around grip for various hand sizes.

The teardrop shape which is replicated in the side, top and rear profiles provides the best ergonomic shape for the handle. Foam models were used to experiment with handle cavity size for the right fit and comfort.

Functioning modes Main battery unit

1 2

1 portable flashlight

Prototyping

The upper section of the lamp separates from the base so that the whole lantern need not be carried around when using it as a flashlight

2 hot and cold

A digital display shows the time and temperature both for indoors and outdoors. Also includes in-built alarm clock function.

3 Adjustable light intensity 3

Adjust the light intensity in number of modes depending upon ambient light conditions.

4 room lighting Auxiliary lantern battery Thermoelectric power unit

Using special mounting accessories to mount the lamp onto the wall to use for general purpose room lighting. (not shown)

Easy thumb slide ON switch

the lamp base unit contains charging dock with fold-in hand crank and solar panel. The other side has a compact AM/FM radio module with adjustable knobs

The handle contains a convenient slide switch at the thumb grip for easy ON/ Off operation of flashlight.

Product form was tested using low and high fidelity foam models. Initial prototypes were used to ideate placement of features and overall product architecture. Later prototypes were made to experiment with and finalize form w.r.t. design considerations

Form & Function

SAVITEJA A portable multi-functional solar lamp

The organic teardrop shape gives a clean-cut aesthetic to the overall shape of the lamp such that the handle doesnâ&#x20AC;&#x2122;t jut out like in other boxy portable lamp designs. With sleek styling and high utility, Saviteja is the ideal solar lamp for every household.

Eco-friendly

Contribute to saving energy for lighting with Saviteja, using minimal amounts of energy and independent of conventional inefficient energy sources

Hassle-free charging

No need to rely on just one source for charging the battery: Use the inconspicuous solar panel, or the easy-to-use hand crank, or just plug it into the socket when thereâ&#x20AC;&#x2122;s power!

sachin.bijadi@gmail.com | 612-532-5852 | Sachin Bijadi

a unique pen holder 3D Printing is a rapidly developing technology that is becoming more accessible and inexpensive day-by-day. It is an interesting challenge to design a gift item that is to be manufactured solely by 3D printing, forcing a designer to work with unique material, cost and design constraints.

CHALLENGE: Design a unique gift product for sale at the Weisman Art Museumâ&#x20AC;&#x2122;s gift store at the University of Minnesota

The Weisman Art Museum at the U of M is a unique landmark designed by architect Frank Gehry. The stainless steel skin on the museum gives it a unique identity.

WAM has a sparkling gift shop with unique designer items. WAM often challenges students to design their own item that theyâ&#x20AC;&#x2122;d want sold in the store.

INDIVIDUAL COURSE PROJECT PDes 5170 Innovative modeling and rendering for Design

SPRING 2013 | U of M

A wide variety of gift products and trinkets are sold at the store - designer jewelry, WAM-themed stationery, t-shirts, jackets, pottery and ceramics, all WAM-branded.

The manufacturing process is fixed as 3D printing. This is ideal for lowering manufacturing costs as the WAM gift shop only makes them in small batches

Flower vases

IDEATION

Desktop trinkets

pen holders

Containers

Connecting joint (to Base)

BASE

nt! r you wa tomlo o c y n s A ntage of cu

S Connecting joint to top ring

Support member printed in the shape of a regular HB pencil

3 Parts make a Pen holder!

adva ct Thereâ&#x20AC;&#x2122;s the f the produ o r lo o c e ization as th lled by the use of ntro g the can be co types durin c ti s la p as s variou elf as well s it s s e c ro comprinting p e printed th r e v o ost. painting marginal c a t a t n e n po

The components were printed using a Dimension 3D printer. The components were so modeled and oriented so as to consume least amount of material - both the structural as well as filler materials. This drastically reduces the printing cost, thus making it viable to batch produce this product through 3D printing.

Minimalistic Pen holder design From the initial hand sketches and simple 3D CAD model ideas, pen holders was chosen as the item of interest since they are very utilitarian in day-to-day usage. Different pen holder ideas were sketched & modeled to explore form: planes/sections; minimalistic; novelty designs; enclosed volumes. The Minimalistic design direction was chosen because not only does it resonate with the Weisman art museum but it also helps use the least possible material, thereby reducing printing costs. The design consists of 2 hexagonal rings forming the volume of the pen holder with the lower piece providing the base for pens to stand on and the upper ring making up the constrained volume of the pen holder. These two pieces are connected together by another member in the shape of a standard pencil, thereby making it look like the upper ring is suspended in air! Assembling the parts together is very easy as the parts click into place and they can be glued at the joints. The pen holder is considerably strong in spite of its reduced weight as the pencil component acts as the load bearing member.

Sachin Bijadi | 612-532-5852 | sachin.bijadi@gmail.com

Simplicity Unique aesthetic

The two pieces of the pen holder are connected together by a support member in the shape of a standard pencil, thereby making it look like the upper ring is suspended in air!

Strong and durable

The pen holder is made of ABS plastic, and the design has been so made as to reinforce the support member to make the entire structure very rigid and strong and not easily susceptible to damage.

Highly functional

The top ring is so designed as to constrain you pens into the volume of the pen holder. Now you can see which pen you are picking from afar when your pen holder is full without having to peer in and search for the right pen every single time

Low-cost of production

Due to its unique design, â&#x20AC;&#x2DC;Simplicityâ&#x20AC;&#x2122; uses very minimal amount of material for both the structural and filler materials during the 3D printing process, because of which the cost of the pen holder is very low even for low volumes of production as compared to plastic products which need to be manufactured in high volumes because of the tooling costs

Sachin Bijadi | 612-532-5852 | sachin.bijadi@gmail.com

sachin.bijadi@gmail.com | 612-532-5852 | Sachin Bijadi

a retro high-performance gaming console As Gaming consoles become more and more powerful, there is extra demand for developing more efficient cooling system. Here the concept design not only needs to convey a retro theme while indicating its high performance nature, but also be energy efficient.

CHALLENGE: Develop Concept Design for a new retro high-performance gaming console

The theme of the console is retro: a throwback to the origin days of game consoles. The console is part of a high-performance gaming package to be launched by a start-up.

INDIVIDUAL COURSE PROJECT PDes 5170 Innovative modeling and rendering for Design

The console shell has to be designed so as to be large enough to fit the motherboard for the console, in this case the handy, efficient and small-sized Raspberry Pi

SPRING 2013

The internal components (motherboard, electronics, etc.) constrain the form of the shell and need to be cleverly utilized to add to the design instead of hinder it.

Form exploration - hand sketching & CAD Retro theme

The inspiration for a retro theme for the console concept design are items from the 60â&#x20AC;&#x2122;s and 70â&#x20AC;&#x2122;s. Considering that this was the age of rock and roll, I explored the fluidic organic classic shapes of electric guitars from the era. Using simple hand sketches for initial exploration, I then used surface modeling in Solidworks to define the shell that could house the Raspberry Pi (fit ensured with CAD model of raspberry Pi). Modeled based on the solid body of a 1970s guitar, I experimented with the shell surface contours and light reflection patterns till I obtained a seamless organic congruent shape. Brushed aluminum was chosen for the shell because of the premium feel which conveys a sense of futurism with a retro shape. Green LED accents were added to increase functionality as well as the aesthetics.

Sachin Bijadi | 612-532-5852 | sachin.bijadi@gmail.com

XETA 490f Power ON

Sleek metallic-accented back-lit power button is soothing to the touch. A clear LED panel on the power button indicates when the console is running.

Plug-n-Play

Plug in any hand held controller of your preference for an unparalleled gaming experience.

Health Monitor

Back-lit metallic logo on the front fins provides visual monitoring of the state of the console and turns red to signal that the device might be overheating and needs to be cooled for a bit.

Power ON

Improved heat dissipation through strategic vent placement and design ensures the device remains cool for a longer time >> increased playtime!

Sachin Bijadi | 612-532-5852 | sachin.bijadi@gmail.com

sachin.bijadi@gmail.com | 612-532-5852 | Sachin Bijadi

that which is remembered.... College is a wonderful time! 4 years of bliss. New friends. New places. Freedom from parents..... This work was conceptualized as a feature length film to record the memories of college. â&#x20AC;&#x2DC;Smritiâ&#x20AC;&#x2122; is the annual effort of the graduating class in making a movie capturing the stories of the new graduates over 4 years of college.

52 THE M2 SAGA It is a tradition that every year the graduating class of NITK commemorates the feat of graduation with a short movie bringing to life the mischief of the newly-crowned college graduates over the past 4 years. This is archived under the “SMRITI” series of films made by graduating students. ‘52’ was created by the Mechanical engineering graduating batch of 2010. Led by a creative team consisting of myself as the Director and editor, and Shridhar who wrote the screenplay and assisted with cinematography, 52’s cast consisted of the members of M2 Mechanical engineering class. Consisting of 8 chapters the full-length feature film portrays the various phases of college life of 3 protagonists who face the challenges of Mechanical engineering with a ‘never-say-die’ attitude.......

Watch the trailer: http://youtu.be/7Bo0XB7Na34

VFX Visual effects was used as a means to convey the tone and feel of the movie through a 2 minute trailer. A compelling story is advertised through simple titles on each CGI shot. Compositions were created using Adobe AfterEffects and the woven into the footage shot with a handheld camera to create the complete trailer. Here CGI was used as an important facet of the storytelling process.

Sachin Bijadi | 612-532-5852 | sachin.bijadi@gmail.com

sachin.bijadi@gmail.com | 612-532-5852 | Sachin Bijadi

an improv sketching battle! Sketch-off is the annual improv sketching battle held at the College of Design at the University of Minnesota - Twin Cities. It is a battle between industrial designers from industry and current and past students of the â&#x20AC;&#x2DC;Concept Sketching & Renderingâ&#x20AC;&#x2122; course taught by Prof. Barry Kudrowitz who leads the Product Design program.

SKETCH-OFF! The improvisational concept battle, organized by Barry Kudrowitz, assistant professor in the Uni

ver-

sity of Minnesota’s College of Design, pits team

s of

artists against each other in a series of speed-drawing product development challenges. Just like “Wh

ose

Line,” all the products being doodled are made up and the points don’t matter.

INDIVIDUAL COURSE PROJECT PDes 5703 Product Form & Model Making | U of M

FALL 2013

a premium multi-purpose sports-axe Camping is one outdoor activity that draws all kinds of people - young to old, amateurs to savvy proâ&#x20AC;&#x2122;s. An essential camping activity is making fire - which requires an axe for making firewood. This project looks at ways to make the camping axe highly specialized and multi-functional while providing personality to match that of the person wielding it.

NEED-FINDING Camping theme

The aim of this project was to design a camping-related product concept that addresses problems faced in camping through a novel design/solution.

STORAGE

CAMPING SHELTER

HEAT & LIGHT

From one-on-one interviews with avid campers, experts and interaction with outdoor store personnel, there were 3 main areas of camping to explore. Inspired by a story I heard from a group of friends who had once gotten lost in a forest full of grizzlies on a dark night without any heat or light to keep them warm and safe, I decided to explore opportunities for novel solutions w.r.t Heat & Light. From initial brainstorming came the idea of developing a multi-functional axe by combining the functions of a lantern and a camping axe into one simple integrated product: the Lite-Ax!

MARKET RESEARCH

Target Consumer: Demographics: 25-35 yrs old; High disposable income Attitudinal segment: Qualityconscious Psychographics: • Values quality products & spares no expense • Resourceful & adventurous • Hardworking and highly active • Experiencer: Willing to take risks

Ergonomics:

By experimenting with multiple sketch models, the form of Lite-ax was selected to mimic the natural power grip of the hand. Material selection: The handle is made of high quality rubber with grooves for easy ventilation. The handle is made from high quality plastic with hollow top & bottom ends to reduce wt. without compromising on strength.

Piezo-charging occurs due to the to-n-fro motion of the axe and vibrati ons of axehead during use. This powers the LED lamp.

MODES

Lite-ax can function in 3 different modes: 1. Axe for chopping firewood 2. Remove the axe-head, twist and pop open the LED lamp inside, extend the handle to convert it into a lantern pole 3. A staff with GPS beacon for hiking in extended mode!

LITE-AX Sport Axe

LED Ambient Light

1 Piezo-charged lamp

Vibration of axe-head within its housing during wood chopping charges the diffused ambient light LED lamp

2 Sturdy axe-head

Carbon steel head: Lightweight, minimal wear and tear. Can be removed easily to use the LED lamp

Walking stick+ GPS Beacon

3aesthetic shape

Curved shaft with sporty aesthetic, helps reduce effort by leveraging more torque and better clearance

4 ergonomic handle

Ergonomic shape with soft rubber padding and sturdy plastic grip ensures easy handling and minimized stress

INTER-DEPARTMENTAL PROJECT NITK Innovation Center |

Project 0CTAVE |

2009-10

a novel solution for reusing printed paper Conventional paper recycling needs separate processing units causing more pollution and energy consumption for transport, sorting, cleaning and storage. Moreover it cannot retain the initial quality of the paper. There is tremendous opportunity for a compact recycling unit which can be used in offices/homes/copier stores, and provide instant recycling.

Industrial paper recycling methods, while effective, aren’t the most efficient ways to recyle paper. The technology can however be scaled down to encourage grass-roots level paper reuse instead of community-level recycling. Conventional paper recycling needs separate processing units causing more pollution and energy consumption for transport, sorting, cleaning and storage. It cannot retain the initial quality of the paper. Another major disadvantage: Recycling is not cost-efficient if done on a small scale.

A compact handy unit for recycling and reuse can encourage localized paper recycling at homes or offices. Subsequently there is increased awareness to reuse high quality printed paper, thereby cutting down on the rate of environmental impact from the paper industry.

Impact on the environment: Each year more than 20 million trees are consumed for production of book papers and about 95 million trees are consumed for newsprint. Deforestation is the source of 25% of human caused greenhouse gas emissions. Over 40% of the global industrial wood harvest is used to make paper.

OPPORTUNITY: REUSE & RECYCLING OF PRINTED PAPER • Developing a desktop device for deinking printed paper will help target the product to individuals/ offices/ homes instead of communities • Using available technology paper reuse and recycling methods can be improved. • There is a need for an efficient design to scale down conventional recycling methods to a customized desktop reverse printer. GOAL: Design a reverse printer for deinking printed paper

CONVENTIONAL PAPER RECYCLING

Sorting

Collection Storage

Recycling centers usually ask for paper sorted by grade and free of contaminants. The collected paper is wrapped in tight bales and transported to a paper mill. This is unloaded and put into warehouses, where it is stored until needed. Forklifts then move the paper from the warehouse to large conveyors.

Cleaning

Re-pulping Screening

Paper moves to the pulper where it chops the recovered paper into small pieces. Heating the mixture breaks the paper down more quickly into tiny strands of cellulose (organic plant material) called fibers. The pulp is forced to remove small contaminants such as bits of plastic and globs of glue.

Bleaching

De-inking

Refining Colorstripping

De-inking removes printing ink. Small particles of ink are rinsed from the pulp with water. Larger particles are removed with air bubbles (froth flotation) where air and surfactants are injected into the pulp, causing them to loosen from the pulp & float to the top of the mixture by mixing with the air bubbles.

Pulp is beaten to make the recycled fibers swell, making them ideal for papermaking. If the pulp contains any large bundles of fibers, refining separates them into individual fibers. Color stripping chemicals remove the dyes from the paper. Pulp may need to be bleached with chemicals to make it whiter and brighter.

Paper making

The recycled fiber can be used alone, or blended with new wood fiber for extra strength or smoothness. The watery pulp is sprayed on a flat screen where water dries and the fibers bond. The sheet moves rapidly through a series of felt-covered press rollers & heated metal rollers which dry the paper.

REVERSE PRINTING CONCEPT The Green Reverse Printer is essentially a compact paper recycler wherein the printed Would you recommend a â&#x20AC;&#x2DC;green reink on the paper is removed without involving the pulp formation stage seen in norverse printerâ&#x20AC;&#x2122; for your organization? mal paper recyclers, hence shrinking the whole unit to the size of a printer. Of Course If it is worth the money.... Depends on my Boss!

No!

Deinking of paper can be done manually by applying the deinking compound and scrubbing the printed area. This could be automated with a simple mechanical design. The problem here lies in the fact that the deinking compound is expensive and its bulk application restricts the usage of this device, cost being an important factor.

then used to optimally apply the deinking compound on the paper in the specified amounts.

Our laboratory trials led to the conclusion that toner based prints could be easily removed with a mixture of Cyclohexane and Acetone in 3:2 ratio as the deinking compound. While complete removal of all The printed area on a used paper is de- kinds of inks remains a distant dream, this tected by optical sensors based on design for A4 sized toner based prints is an LDR and LED. This information is initial step towards that.

sachin.bijadi@gmail.com | 612-532-5852 | Sachin Bijadi

DEINKING PROCESS & SYSTEM-LEVEL DESIGN Schematic:

Components:

1. Paper dock- to house the papers to be deinked 2. A roller drum run by a DC motor (M1) 3. A de-inker head unit comprising of a 14 the deinking compound and an LED-LDR sensor to detect the prints. The whole de-inker head unit is run on a belt with a DC motor(M2) 4. An outlet port - for storing the output deinked paper 5. Internal circuitry - is based on the Atmega32 micro-controller Working Principle: • The A4 sized prints are kept in the dock of the reverse printer. • The power ON and DC Motor enables are activated when the print sensor detects the paper. • A sensor at the opening of the dock sends information and one paper at a time is positioned with the help of DC Motor 1 (M1) into the roller drum‟s hold. This is the first shift of M1. • DC Motor 2 (M2) moves the de-inker head horizontally over a steel rod with a belt. • LDR-LED Sensor data is read for every 14 stoppages horizontally in a line and stored in the specified memory address L.

• M2 shifts for the second time while direction of M1changes. • The solenoid valve is controlled based on the data retrieved from memory address V. The brushing action is also synchronized with the valve control. • After the initial positioning of the paper, M1 shifts 11 times repeating the M2 rotation for every horizontal line in alternating directions. • The 13th shift relieves the paper out of the roller drum hold and is ejected out. The sensor at the opening of the dock detects paper to be deinked further.

PRODUCT FUNCTIONING & ARCHITECTURE Idea generation was done for different methods of deinking. Below is the concept classification tree. While all 4 methods were studied, chemical method was selected for prototype due to easy availability of all required components and deinking agents.

I developed the architecture for the reverse printer based on concept of a conventional printer. Product architecture was made similar to a regular printer with the intention of possibly creating a future product based on teh concept of â&#x20AC;&#x153;printer & reverse printer in same device with interchangeable modules for printing and deinkingâ&#x20AC;? Power consumption Analysis: Deinking capacity of device = 22 copies/hr Monthly volume = 30x200 = 6000 copies Deinking hours = 6000 copies/ 22 per hour = 273 hrs => Monthly power consumption = 20.475 kWh Cost analysis: Estimated cost of device ~ INR 3550/Running costs = INR 82 /month (@ unit electricity cost in India=INR 4/kWh)

sachin.bijadi@gmail.com | 612-532-5852 | Sachin Bijadi

Sachin Bijadi | 612-532-5852 | sachin.bijadi@gmail.com

design of customer-centric concept car interiors the passenger car market is an ever-evolving one. While design drives the development of new products, customer feedback plays a major role in car development. With this in mind, this project looks at ways to study and understand the brand DNA of the players in the Indian automotive market and the needs and requirements of customers, to design and develop a new interior style for family hatchbacks in the A2 market segment.

BENCHMARK STUDY Both features and design philosophy of the A2 Passenger car segment in India were benchmarked to study deployment of key features to satisfy stated customer needs. Perceived quality audits were conducted to convert subjective responses to metrics. A brief snapshot of the styling study undetaken to understand design philosophy is shown below.

Sachin Bijadi | 612-532-5852 | sachin.bijadi@gmail.com

Layout

Illumination & driver info display

car interiors St. wheel geometry

In order to gauge perception of customer to certain disruptive features, a detailed survey was prepared. Responses from approximately 1000 individuals across a varied demographic (customer profile was captured through specific questions included in the survey, for easy segregation and category-wise analysis) were collected. A-Kano analysis was made through functional, dysATTRACTIVE ONE DIMENSIONAL functional and numerical forms of questions. Collected responses were weighted and scored. Functional requirements were identified and Customer needs categorized as attractive, must-be and hygiene. Costing of feaINDIFFERENT MUST BE tures was done to study feasibility of features within assigned cost targets for product. Moon Lighting

Storage box between Driver

Bluetooth Device

Service reminder

Denim gear shift knob

Parking sensor

ergonomics

Anti theft car locator

ORVM turn Indicator

Seat belt height adjustr

Immobilizer

Music System

AC Swing function

Rear passenger space

INSPIRATION BOARD

Volume and power button Mode selection switches

Glass-finish display

Passat central cons

Jetta central console

SKETCHING Based on learnings from Benchmark studies, customer perception survey, cost analysis, and study of ergonomics I compiled all key points into a basic concept cockpit, which can meet all customer stated and implied needs for the A2 passenger car market segment in India.

Sachin Bijadi | 612-532-5852 | sachin.bijadi@gmail.com

FEATURES BASED ON VOC

LOW

MID

HIGH

Sachin Bijadi | 612-532-5852 | sachin.bijadi@gmail.com

using digital simulation for low-cost powertrain integration A vehicle assembly line is a complex system consisting of multiple stations and operations. Using process planning principles work procedures are set. What happens when the line needs to be changed, say when there are new powertrains? Change is costly and planning is difficult. In such cases, using digital manufacturing techniques allows for maximum flexibility in planning at much lower costs.

Chassis marriage process simulation (Vehicle Assembly line 2)

Powertrain integration with the chassis marriage system is a critical operation in the vehicle assembly line The Mfg. planning division in Tata Motors owns the task stream of planning and executing all manufacturing systems and assembly lines necessary for production of vehicles. As part of future product line-up, new powertrains need to be introduced to improve fuel efficiency and reduce weight. This calls for detailed feasibility studies for integration of the new engines in the existing manufacturing facilities of the vehicle assembly shop.

The chassis marriage system enables integration of the powertrain (engine + gearbox) with the chassis of the vehicle . Automated guided vehicles house the system and work in sync with the main assembly line thereby improving productivity.

The powertrain complexity matrix was created mapping powertrain to vehicle, as well as linking each new powertrain to the respective assembly line and chassis marriage system on which it will be used in the vehicle assembly shop

After detailed feasibility studies, tooling on the chassis marriage system was modified/ created . I used Catia & Delmia to model and simulate the assembly line. Ergonomics was tested with Manikin. Manufactured fixtures were then tested in a Tool-Try out lab.

INDIVIDUAL PROJECT Advisor: S. Pimpale, AGM, Technical Services

Spring 2011 Tata Motors Limited, Pune

blind spot assistance - the human factors approach When operating a vehicle, information about oneâ&#x20AC;&#x2122;s surroundings is of the utmost importance. Being aware of the presence of other vehicles and predicting their movements however can be difficult due to the phenomenon of the blind spot. Mirrors insufficiently attempt to give drivers a view of what is around them. When changing lanes on a highway or pulling out from a street side parking space, this lack of information can make drivers uneasy and apprehensive when making a decision on the safety of a maneuver. We look at a novel blind spot indication system for passenger vehicles to alleviate this issue based on a detailed human factors study...

Goal:

Solution:

1. Understand the various parameters involved in changing lanes, and shortcomings due to blind spot

Our system proposed a Time-to-collision (TTC) based approach, utilizing the information gathered from peripheral sensors on the car to measure speed and distance of adjacent cars dynamically and map the TTC. In sync with calculated TTC, a simple color coded LED display system relays info to help the driver in decision making regarding lane change.

2. Developing a solution to help: • increase comfort level in lane changing • improve safety by improving the relay of necessary information • providing this information in a way that is both cognitively digestible and clear in its implication

Comparison of workload related factors with old and new designs respectively (above) & No. of adverse events (below)

Testing was done at the HumanFIRST simulation lab. Fly-on-the-wall observation and qualitative/ quantitative surveys were used to collect data. NASA-TLX Index was used. Results showed that blindspot assistance improved driver comfort and reduced mental workload and effort.

TEAM COURSE PROJECT ME 5211: Human Factors & Work Analysis

FALL

2012 | U of M

ergonomic actuator device for biopsy forceps Used widely by medical professionals for a multitude of clinical requirements, biopsy forceps are actuated using an actuator device which is held stationary in one hand while the other is used for related clinical tasks. Due to the nature as well as long duration of use, a badly designed actuator can cause stress and fatigue in the hand. BI-EN is designed to achieve more ergonomic operation of the biopsy forceps with a simple actuation mechanism promising smoother operation & better reliability

BI-EN The goal of this project is to design an actuator device to effectively and easily operate biopsy forceps in surgical use that are different from the current devices available in the market. The device helps the surgeon to actuate (open and close) the biopsy forceps with either one hand or 2 hands. This is accomplished by first feeding the forceps and cable into the body and then pulling on the wire cable to close the jaws of the forceps.

1 Ergonomic grip

The 3-finger pinch grip allows for the thumb to go over the main tube while 2 fingers hold the top clamp, providing for a comfortable yet powerful grip. Rubber paddings provide comfort for fingers.

2 Smooth travel & locking

5 Smaller footprint

the clever 2 piece design allows for a smaller device size and hence makes it easier to store and operate

since the 2 parts slide effectively in a straight line over each other the travel is efficient and smooth

g Creo

del usin

3D mo

3 Light-weight

4 Aesthetics

the long drawn plastic parts & patterned rubber grips provide nice contrast and feel to the surgeon using the device. Unique design ensures strong & robust actuator.

the design incorporates minimal material and provides both functional and aesthetic material removal patterns on the body

INDIVIDUAL COURSE PROJECT ME 5241: Computer-Aided Engineering | Nov. 2012 | U of M

sachin.bijadi@gmail.com | 612-532-5852 | Sachin Bijadi

a premium multi-functional urban stroller The City Sherpa stroller is an innovative and elegant solution that solves top complaints on the market– ‘there’s never enough storage’; ‘there isn’t any room for my other kid(s)’. Current competitive products do not address the needs of versatile storage or multiple expandable seating options for a second child - in essence, a stroller for all occasions.

University of Minnesota New Product Design & Business Development

City Bébé Ltd.

Project Lead

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