JAZZY. SELECT ELITE. POWER WHEELCHAIR. This project encompassed the design and development of a new power wheelchair for Pride Mobility Products that is both economical and versatile. Do more with less. This was the central theme of the project and a sign of the times. A heavy emphasis was placed on design simplicity and minimal part count. Iconic look. Frame and plastics needed to work in unison to establish a unique and iconic Jazzy look. This new design language would become the foundation for subsequent models to build upon. America’s #1 Power Chair. In production this model met initial design goals and achieved several milestones on its way to number 1.
Pride Mobility Products - Jazzy Select Elite - 2009
Chris Terella - Industrial Designer - cterella@gmail.com
Directives. design goals >
A list of provided corporate directives expressed in the form of wants and needs initiated the design process and established a framework for the engineers and designers to build upon. Low production cost.
Easy to service.
Simple construction.
No suspension.
Placement. lineup >
Strategic product placement can be the dierence between missing or capitalizing on an opportunity. This chair provided an economic, light duty, front-wheel drive option to the Jazzy power chair line.
Competition.
heavy duty
light duty
Merits P120
Merits P320
Merits P321
Shoprider Trooper
Shoprider Jimmie
Golden Alante JR
players in the game > Merits Shoprider Golden
Pride Mobility Products - Jazzy Select Elite - 2009
Chris Terella - Industrial Designer - cterella@gmail.com
Questions.
project structure >
What medically reimbursable class is this product intended for? What are the performance requirements for this class?
Battery selection affects the range or miles per charge a chair can achieve.
Turning radius is detrmined by wheel location and frame geometry.
Tires and wheels alter performance, ride comfort, maintenance + aesthetics.
Seating high or low seat back, head rest, manual recline, or power elevation?
The Jazzy Select is the most successful power chair to date.
Battery removal w/out the need for seat removal is a good service feature.
Part separations, seams, and screw holes can make cleaning difficult.
9 plastic parts for the Jazzy Select. Can it be done with less?
Removable battery box is convenient for transit.
Brand Identity. Iconic logo. Brand trust. Loyalty. Identification.
Shoprider’s “Jimmie” breaks down into 3 manageable parts.
Simple tool-less disassembly.
Evaluation. pros + cons >
What areas of the current Jazzy Select have proven successful and what areas reveal opportunity?
What can be learned from competitor’s strengths and weaknesses?
Pride Mobility Products - Jazzy Select Elite - 2009
Chris Terella - Industrial Designer - cterella@gmail.com
Ideation.
brain storming > With corporate directives and primary goals identified, I begin to conceptualize various design ideas with the team’s mechanical engineer.
>
inspiration
Pride Mobility Products - Jazzy Select Elite - 2009
Chris Terella - Industrial Designer - cterella@gmail.com
Style.
form development > A fresh new iconic look was the vision for this chair. To achieve a unique visual identity a dynamic top surface became the focal point of our designs. Key words were established to keep explorations on track.
+ Sporty + Flowing + Simple + Clean
inspiration > The idea of a smooth flowing surface separating to reveal something powerful beneath became an inspiring direction. Visual references to power can be seen in the automotive and electronics market.
Pride Mobility Products - Jazzy Select Elite - 2009
Chris Terella - Industrial Designer - cterella@gmail.com
Compilation. general assembly >
solid welded tubular frame
top shroud (ABS)
VR2 controller anti-tip wheels
1 solid frame 3 major plastic components The frame became an integral part of the design, complimenting the plastics rather than just being covered by them. Striving to do more with less, each component was challenged to contribute to both the functional and the aesthetic aspects of the design. All parts were scrutinized and refined several times resulting in a simple unified solution.
nose shroud (ABS) drive wheel
battery tray (nylon+5% glass ďŹ ber)
components > Strong efforts were made to reduce fastening hardware and assembly time. Only four screws are needed to secure the nose. Thumb screws, interlocking geometry, and snap features secure the rest.
Pride Mobility Products - Jazzy Select Elite - 2009
Chris Terella - Industrial Designer - cterella@gmail.com
Battery Tray. under the hood >
On the surface this part looks simple, but the technical requirements and engineering details easily make it the most complex assembly on the chair. Suspended between the frame’s two main rails and required to carry a significant load (two lead acid batteries), this plastic battery tray had to be designed for strength.
quick release electrical connector
battery secure strap (PP) click feedback feature
terminal cover
rail support feature thumb screw reflector branding badge
Exposing the side frame rails not only created a strong design element, but enabled the battery tray to easily slide out for removal. pull handle
easy servicing > Easy as 1-2-3... Disconnect the electrical “quick connects”, loosen the thumb screws, grab the handle, and slide out the tray.
Pride Mobility Products - Jazzy Select Elite - 2009
Chris Terella - Industrial Designer - cterella@gmail.com
Tires.
traction + comfort > Material, size, and tread geometry all contribute to a tire’s performance characteristics. Indoors- tires need to run smoothly on hard floors and minimize wear on carpets. Outdoors- tires need to overcome small curbs, obstructions, and moderately wet conditions.
Wheels.
style + strength > Designing a 6 inch plastic rim with a 300 lb. weight capacity that was also stylish had its challenges. Many designs were explored from the ornate to the simplistic, but were governed by strength and manufacturability. Ultimately a clean six spoke design was selected.
tire gate location
rim (nylon+15% glass ďŹ ber)
aluminum
Tire (PU) foam
Pride Mobility Products - Jazzy Select Elite - 2009
Chris Terella - Industrial Designer - cterella@gmail.com
Renderings. presentation >
Hypershot renderings of the new chair were created for presentation meetings held by the design, sales, and marketing teams. These images made it possible for anyone to visualize a realistic end product long before prototyping or tooling investments were made.
Pride Mobility Products - Jazzy Select Elite - 2009
Chris Terella - Industrial Designer - cterella@gmail.com
Possibilities. options >
Switch it up. Try a new look whenever the mood strikes you.
Let’s face it. We get bored with the same old thing. We wish to be current and unique, and desire a style that best reflects who we are. Style matters. Pop off the main shroud and switch it up. From classic to exotic, bold to understated, the sky’s the limit - one part has never changed so much.
maintenance >
LARGE SURFACE. PAINT OR WATER TRANSFER FILM
EASY FIX. BROKEN SHROUD - SNAP ON REPLACEMENT
Serviceabilitly is a big issue for power chair users. The shroud was designed for tool-less assembly and replacement. A seamless removable surface also makes it easy to clean up dirt and spills.
EASY TO CLEAN. NO PART LINES
Pride Mobility Products - Jazzy Select Elite - 2009
Chris Terella - Industrial Designer - cterella@gmail.com
Prototype. ďŹ t + ďŹ nish >
For this chair all the plastics STL files were sent out to a rapid prototyping firm. SLS (Selective Laser) and SLA (Stereo Lithography Apparatus) were chosen because of the strength and finishing characteristics respectively. With parts in hand, test fitting of the complete chair takes place. Everything is evaluated, from strength and function to fit and finish. Issues are identified and tweaks are made before sanding and painting the parts. Adding labels and decals completes the working presentation prototype.
Testing.
strength + durability > Every chair has to pass a series of tests. Some are Pride’s while others are mandated by the FDA. Cycle, drop, weight, and range are just a few common tests performed.
Pride Mobility Products - Jazzy Select Elite - 2009
Chris Terella - Industrial Designer - cterella@gmail.com
Marketplace. for sale >
The Pride Jazzy Select Elite Power Chair delivers a reliable blend of power, performance, and style in an affordable, durable package. The unique articulating rear frame and front-wheel drive combine to provide a stable and secure ride with excellent maneuverability and torque.
>
key features
+ Simple main frame design for easy serviceability. + Easy access to batteries from rear. + Depth adjustable foot platform. + Tool-less shroud removal. + In-line, front-wheel drive technology. Pride Mobility sells its product through various independent providers. In this case The Scooter Store sells The Jazzy Select Elite with ďŹ nish and decal alterations as the TSS 300.
Pride Mobility Products - Jazzy Select Elite - 2009
Chris Terella - Industrial Designer - cterella@gmail.com
E CLIPS . ACTION. VIDEO CAMERA. Capturing, saving, and sharing our experiences with others has always been a human desire. Today, thanks to online social networks and web sites, the transition from capture to publication is so simple anyone can do it. As a result, the video camera marketplace is expanding at a rapid pace. Focus. In-depth knowledge of the intended audience often uncovers revealing opportunities. What is the DNA of this group? What factors in a new product matter most to them? Simplicity. Often the most difficult challenge is to make the complex simple. All facets of this design were evaluated for simplicity. Identity. The aesthetics of this camera were inspired by the outdoor enthusiast. The fit and finish complement the objects it attaches to while maintaining its own desirable identity.
SpeciaLTDesign - Action Video Camera - 2010
Chris Terella - Industrial Designer - cterella@gmail.com
Identification. who >
+ Thrill seeker + Active participant + Outdoor adventurer + Weekend warrior
>
design goals
The videographer is an active participant
Small size and good quality
Withstand the elements
SpeciaLTDesign - Action Video Camera - 2010
Chris Terella - Industrial Designer - cterella@gmail.com
Marketplace. choices >
CROSS COMPARISON
Advanced/Professional Camcorders
Price
HD Helmet Camcorders
HD Pocket Camcorders
HD Handy Camcorders
Analysis of the digital video camera market reveals the strengths and weaknesses of existing offerings for use as an “Action” video camera. The new design strives to incorporate a combination of desirable attributes not found in competing products.
SpeciaLTDesign - Action Video Camera - 2010
Sony HDR-AX2000 - Model highlights: 1920 x 1080/60i, film-like progressive scan 24p/30p, superior low light, wide-angle G Lens, image stabilization, 3 built-in neutral density filters, XLR audio inputs
Picture quality
Ease of use
SUBPAR
Features
EXCELLENT
Durablity
Portability
$ 3499.99
Canon XL2
- Model highlights: 16:9 and 4:3 aspect ratio shooting formats (962 x 480) x3 CCD & (720 x 480) x3 CCD. PCM digital recording: 16 bit (48 kHz/2 channels); 12 bit (32 kHz/4 channels). XL interchangeable lens system. And much more.
$ 3999.99
The Canon VIXIA HF S11 -Model
highlights:1920 x 1080 Full HD. 64GB internal flash drive & SDHC card slot. Canon 10x HD Video Lens.24Mbps Recording. Dynamic SuperRange Optical Image Stabilization
$ 1399.99
JVC Everio GZ-HD 300B -Model highlights:
HD1920 x 1080P Recording. 60GB Internal Hard Disk Drive. 1920 x 1080 Digital Stills. One-touch Upload to YouTube, PC, DVD Creation, MediaBrowser
$ 699.99
Sony HDR-CX150/R - Model highlights: 1920
x 1080 Full HD video recording, 3-megapixel images, 16GB embedded Flash memory, “Exmor R” CMOS sensor, Smile Shutter™ technology, Face Detection, Direct Copy, 25X optical zoom
$ 549.99
JVC Picsio -
Model highlights: :Simple and enjoyable Pocket Camera with an SD/SDHC card slot, featuring 1080P HD video recording, 8 Megapixel stills, Digital Image Stabilizer, and direct file sending to YouTube(TM) and iTunes(R)
$ 199.99
Flip MinoHD- Model highlights:
120 minutes HD video 8 GB of built-in memory. Internal lithium ion battery. 2.0” display. Upload video to Facebook, MySpace, YouTube. 6:9 HD 720p (1280 x 720) at 30 fps. MP4 files
$ 229.99
Sony Bloggie CM5- 1920x1080 high definition
MP4. 5x optical and 20x digital zoom. 5MP Stills. Compatible with Memory Stick PRO-HG Duo™ media or SD/SDHC cards. Easy playback. 32GB card can store up to five hours of HD footage. It plays nicely with sites like YouTube, and Facebook.
$ 199.99
Hoyttech HCR-100X- Model highlights:
HCR100X helmet cam records at a high bitrate of 5-6Mbs @ 30 FPS in High resolution mode. interchangable lenses 3.6mm wide angle. 2.9mm, 6mm and 8mm lenses. Instantly playback on 2.5” display.
$ 399.99
GoPro Hero HD-
Model highlights: 1080p-1920x1080@127º. 960p-1280x960@170º or 720p: 1280x720@170º both 30 and 60 fps. 5MP Time Delayed Photos. SD card. MP4 recording. Polycarbonate housing Waterproof to 180’ Lithium-Ion Battery. USB
$ 299.99
Chris Terella - Industrial Designer - cterella@gmail.com
scale
>
Sketches.
This rough model represents a form factor that is comfortable to hold, and establishes a starting point for sketch development.
exploration > These sketches explore various forms and contextual inspirations in order to further expand the concept of a tough, yet reďŹ ned appearance.
SpeciaLTDesign - Action Video Camera - 2010
Chris Terella - Industrial Designer - cterella@gmail.com
Sketches. ideation >
These perspective renderings bring a form and feel to the camera, while component development and functionality are also explored.
SpeciaLTDesign - Action Video Camera - 2010
Chris Terella - Industrial Designer - cterella@gmail.com
Camera. E-Clips >
The E-Clips video camera was designed for the action sports enthusiast who wants to capture the fun but also participate.
>
features
waterproof. weatherproof
mounted or handheld
limited dexterity operation USB
Li-Ion battery. USB connection
1080P HD video. MicroSD Card
Bluetooth remote control
downloadable App
SpeciaLTDesign - Action Video Camera - 2010
Chris Terella - Industrial Designer - cterella@gmail.com
Camera. exploded >
The simple design strives to keep the part count, cost, and complexity to a minimum. Whenever possible, complementary parts were designed symmetrically to minimize tooling costs.
PART
>
bill of materials
DESCRIPTION
MATERIAL
A
OUTER SHELL
ALUMINUM SHEET 6061 T6
1
B
MAIN BODY
ASA
2
C
RELEASE BUTTON
ASA
2
D
RELEASE LIFTER
PC+ABS BLEND
1
E
STOP START BUTTON
SHORE 50 A TPE
1
F
CAMERA BARREL
ALUMINUM TUBE 6061
1
G
SUN VISOR
SHORE 70 A TPE
1
H
LENS ASSEMBLY
NA
1
I
CAP O-RING GASKET
SHORE 75 A NBR
1
J
REAR CAP ASSEMBLY (CAP + LIGHTPIPE)
ASA ACRYLIC
1
K
ACCESSORY COVER
PC + ABS BLEND
1
L
BARREL SLEEVE
ASA
2
M
CIRCUIT BOARD
NA
1
N
LI-ION BATTERY 3.7V
NA
1
O
CIRCUIT BOARD MOUNT
PC + ABS BLEND
1
P
TORX SEX BOLT SET 8-32
STAINLESS STEEL
2
STAINLESS STEEL
6
STAINLESS STEEL
2
Q R
PHILIPS PAN HEAD STAINLESS STEEL 4-24 x 1/4” PHILIPS FLAT HEAD STAINLESS STEEL 4-24 X 1/4”
QTY
SpeciaLTDesign - Action Video Camera - 2010
sealed barrel
lens assembly
rotation
water tight protection for the camera’s vitals.
2.8/5 Lens assembly with Carl Zeiss optics.
Chris Terella - Industrial Designer - cterella@gmail.com
Communication. Bluetooth remote >
No need to blindly search for the camera’s record button. Simple start and stop operations can conveniently be performed with the Bluetooth remote at a moment’s notice - even while wearing gloves.
>
LED indicators
Is it recording? Guess no more! Green and red LED lights announce recording, memory, and battery life status on both the camera and remote.
RECORD / MEMORY STATUS LED
RUBBER EDGE
STOP / START REC POWER ON/OFF BUTTON
MINI USB PORT
BATTERY / COM. STATUS LED
NYLON WEAVE
ON SOLID
BLINKING
OFF
RECORDING
LOW STORAGE
NOT RECORDING
GOOD BATTERY IN BLUETOOTH RANGE
LOW BATTERY
NO POWER OUT OF BLUETOOTH RANGE
SpeciaLTDesign - Action Video Camera - 2010
mini USB charging
Chris Terella - Industrial Designer - cterella@gmail.com
Mounts. attach + adjust > The E-Clips mounting system is designed for fast attachment, removal, and adjustment. The curved mounting track on the camera makes this possible. By squeezing the large release buttons the locking tab disengages, allowing the camera to rotate freely up to 60 degrees or to be removed - regardless of the mount used. suction mount
strap mount
universal mount + 90 o mount
lock / release tab
large buttons
Squeeze the buttons to adjust or remove the camera.
SpeciaLTDesign - Action Video Camera - 2010
curved mounting track
This allows the camera to be aligned up or down quickly.
Chris Terella - Industrial Designer - cterella@gmail.com
Storyboard. >
snowboard trip
SpeciaLTDesign - Action Video Camera - 2010
Chris Terella - Industrial Designer - cterella@gmail.com
TRU COMFORT . POWER CHAIR. SEAT BACK. The Tru Comfort seating system has developed a reputation for providing quality seating solutions to accommodate a wide variety of users and their individual needs. These seats are designed to provide comfort and style, yet still remain highly configurable. Sizes. In a competitive market, sales can be won or lost depending upon option availability. In this case, offering more seating sizes would expand the market, and hopefully generate additional sales. Integration. The new design focused on visually integrating the seat back and power base. Form language and color consistency helped unite these previously dissimilar systems. Configuration. Power seating systems are complex creations. Lift, tilt, and recline movements are powered by various electronic controllers mounted in the seat back. Numerous other power options, accessories, and add-ons make for a dizzying number of configurations.
Pride Mobility Products - Tru Comfort Seat Back - 2011
Chris Terella - Industrial Designer - cterella@gmail.com
Context. what is a seat back ? > From a distance power chairs can appear similar, but closer examination can reveal some distinctive differences. Pride’s power chairs are typically broken down into two primary components: the Seating System and the Power Base. Both components come in a variety of sizes and a wide selection of features that combine to make unique configurations to address specific user needs.
Power Chairs come in an array of configurations to meet the varying medical needs of wheelchair users.
Challenge. seat back sizes > The Tru-Comfort seating system has emerged as a successful product offering from Pride Mobility. Despite this the sales team reported losing power chair sales to competitors as a result of not offering more than the current 8 seating sizes. To build on the success of this product line, and gain sales, 24 additional sizes were required.
8
Seat back sizes currently offered.
Seating Systems + Power Bases easily interchange enabling a wide variety of customization.
The Seat Back is one component of the seating system. - Also offered in a variety of sizes and configurations.
SEAT SIZE MATRIX
+ 24
New seat back sizes requested.
= 32 Total size offerings
Pride Mobility Products - Tru Comfort Seat Back - 2011
Chris Terella - Industrial Designer - cterella@gmail.com
Established.
Adjustable Headrest
Push Handles The Tru Comfort push handles provide a comfortable rubber grip surface for pushing and manoeuvring a power chair. Not only is this handle a favorite of many care-givers, but it is also extensively used for the hanging of personal backpacks and other accessories.
This adjustable headrest is a standard component on the original Tru Comfort seat back, and an option on other seating systems. The headrest is fully adjustable to provide optimal fit and support.
component carryover > With the success of the Tru Comfort seating system, many of the high volume components needed to be carried over to the new design.
Accessory Controller
Cantilevered Arm Rest The recently introduced cantilever arm option was projected to be present on 80% of the arm configurations for the Tru Comfort seat back. The arm angle can be quickly adjusted and flipped-up for convenience in seat transfers. New seat backs were required to accommodate these arms.
The accessory controller is the primary device responsible for controlling all the power options in the seating system. Power options include articulating leg rests, power tilt, power recline, attendant joystick controller, and extended display to name just a few.
Tester Circuit Board
T- Slot Mount The tester circuit board is a high volume component that is installed on every power seating system. This serves as a manual override switch to all seat positioning electronics such as power tilt, recline, and leg rests articulation. If the primary accessory controller fails, this device can be used to perform the same functions.
Pride Mobility Products - Tru Comfort Seat Back - 2011
T-slot rail mounts are an integral part of many Quantum base seating solutions. This common mounting system allows for a variety of interchangeable options and seating configurations. The new Tru Comfort backs needed to utilize this mounting system.
Chris Terella - Industrial Designer - cterella@gmail.com
Research. location >
objectives
Pride Mobility’s plant in Duryea, PA handles everything from general assembly to complex special orders. Each unique order is hand-assembled and tested before distribution. This is where the Tru Comfort seating systems are conďŹ gured and attached to the power chair bases.
Observe seat assembly process Document the assembly process Talk with the assembly workers Identify potential opportunities
>
Tru Comfort seat installation
+ + + +
1
2
Next, the assembly team slides the seat back onto the power base rails.
3
Mounting bolts are tightened to secure the seat back to the rails.
5
First, components and accessories are compiled on mobile carts and then wheeled through the assembly process.
Pride Mobility Products - Tru Comfort Seat Back - 2011
Electronic controls are installed to manage power seat and accessory options.
4
Armrests are then fastened to the rails, completing the basic build.
6
Wires that connect to the controllers are gathered, bundled, and routed.
7
Finally, the cover is attached completing the electronics installation.
Chris Terella - Industrial Designer - cterella@gmail.com
Research.
2
1
opportunities >
Sometimes taking a second look can reveal opportunities missed at first glance. In most cases the electronic controllers fit comfortably into the provided location. However, when observing some of the more heavily optioned configurations, assembly was clearly not so easy. This technician demonstrated some of the challenges he faced with a tight installation, which provided some key insights for the new design.
Wires need to be gathered and packed while holding the controller.
Assembling a seat back can be challenging when faced with a hairball of accessory wires.
3
Inserting the controller can be tough on the fingers.
4
Carefully slide the controller into place without disconnecting wires.
5
6
7
Fastening can be difficult. The tight confines result in dropped screws.
Re-inserting a forgotten or lose wire is often problematic.
No room to store the wire pack required for tester board operation.
odds + ends > These pictures represent a sampling of various considerations carried forward into the design phase.
Tools used in the assembly process can influence the part design.
Pride Mobility Products - Tru Comfort Seat Back - 2011
Blind adjustment screw hidden beneath the seat back Velcro.
One of the many accessory options to consider.
There are many accessory wire configurations.
The storage and organization of current seat back pans.
Chris Terella - Industrial Designer - cterella@gmail.com
Tiny.
challenges
start small >
A tight fit! In SolidWorks the smallest seat configuration revealed the most challenging fit requirements. This became a logical starting point for design exploration. Viable solutions at this small scale would provide a successful frame work for larger size configurations.
18”
suggestions Original Tru Comfort handles would not fit properly at this narrow width.
Design slightly smaller handles and separate the mount holes.
Headrest post crashes into the tester board. How high does the headrest need to rise?
Offer two headrest post sizes. The short post will be the default for small seat backs.
Tight space for controllers, wires, and other electronic components.
Design a small enclosure box to contain and organize the electrical components and wires.
14”
E-Box.
tester board
What goes into the box?
controllers
components >
Designing one electronic box (E-Box) that could be utilized on all 32 seat back sizes has many advantages. The new E-Box could be constructed to accept all the necessary components in a compact, organized fashion. A wooden enclosure was constructed to test-fit each controller wired in its “worst case scenario”. This exercise helped to quickly determine some rough size requirements.
+ Potential redesign opportunity?
wires
+ The tester board could be made easier to use by anyone. + A new design could be space saving, and possibly mounted in a different location. + Current inventory is being depleted, a manufacturer will need to be sourced anyway.
Pride Mobility Products - Tru Comfort Seat Back - 2011
Chris Terella - Industrial Designer - cterella@gmail.com
Sketches. concepts >
A visual starting point. Sometimes pencil, paper, and a little Prismacolor get the ideas owing.
These sketches were used as talking points for directional clarity and style exploration.
Pride Mobility Products - Tru Comfort Seat Back - 2011
Chris Terella - Industrial Designer - cterella@gmail.com
Direction.
3 different options
A
1 PIECE BACK
B
2 PIECE BACK
C
4 PIECE BACK
Options A, B, and C represent three unique solutions to cover the 32 seat back sizes. Solution A (1 piece back) utilizes 32 plastic shrouds tailored to each size. Solution B (2 piece back) utilizes a right and left shroud set that expands width-wise. Solution C ( 4 piece back) utilizes a shroud on all four corners and expands height and width-wise.
3 different costs The plastics tooling costs were major considerations in the decision making process. Solution (A) would cost millions in tooling for 32 unique parts. Solutions (B) and (C) were considerably cheaper to tool with only a handful of unique parts.
decision point Option B was the chosen direction for it’s balance of edge protection, style, and tooling costs. One solid plastic back per size provides great coverage for optimal fit and finish considerations, but is it affordable or realistic to pursue this option?
Pride Mobility Products - Tru Comfort Seat Back - 2011
The split back design covers all 32 seat sizes with 4 height specific sets. For example the same 18 inch high shroud set is used on widths from 14 to 24 inches.
The four corner design covers 32 seat back sizes with only 4 parts. This is a simple and cheap solution to manufacture, but what about edge coverage and aesthetic considerations?
Chris Terella - Industrial Designer - cterella@gmail.com
Survey.
style 2
style 1
style 3
3 side styles >
Many variations of the 2 piece back were explored yet no single design stood out as a deďŹ nitive favorite. To gain clarity and perspective from others, I conduct a survey of over 50 people.
3 E-Box choices > The participants were asked to place in order of preference the three seat back conďŹ gurations. For example 1C-1A-1B. This was repeated for each style group. At the end participants were asked to identify their single favorite option from all the styles.
1A
1B
1C
2A
2B
2C
3A
3B
3C
survey says ... > most preferred neutral least preferred The results were tallied in Excel and graphically presented.
Pride Mobility Products - Tru Comfort Seat Back - 2011
Chris Terella - Industrial Designer - cterella@gmail.com
Review.
presentation >
The results of the surveyed participants were organized into an informative interactive PDF. I used this in a presentation to help inform management, coordination, and sales staff as to the risks and rewards of various directions. The survey results provided credibility to certain design directions and helped influence the final solution.
closer look > These are a few of the pages pulled from the interactive pdf file. The topics covered: poll results, part count, size matrix, and box configurations.
Pride Mobility Products - Tru Comfort Seat Back - 2011
Chris Terella - Industrial Designer - cterella@gmail.com
Solution.
R side shroud painted (ABS)
exploded view > The direction of four sets of height specific shrouds offered the best balance of edge protection, style, and price. The electronics enclosure and arm rest collars add to the overall part count but are utilized in every size configuration.
back pan powder coat (steel)
overmold (TPE) nylon+5% glass fiber
25”
e box outer lid textured (ABS)
Quantum logo (vacuum metallized)
22” arm rest collar textured (PP)
L side shroud painted (ABS)
e box base (ABS)
e box inner lid painted (ABS)
20”
18” After the middle section is painted the electronics box lid easily snaps together. No tools required.
Pride Mobility Products - Tru Comfort Seat Back - 2011
The side shrouds and arm rest collars interlock over a shared screw mount. This helps expedite and simplify the assembly process.
The part break-up and finish transition helps divide a bulky location into an appreciated design detail.
Chris Terella - Industrial Designer - cterella@gmail.com
E-Box.
1
assembly steps > In designing the electronics box a strong effort was made to address the key issues uncovered during the research phase. Several of these insights resulted in design improvements that were welcomed by the assembly staff. Many of the buildup steps can now be done prior to the final assembly.
4
Align the plate with the notched holes in the back pan. This allows the plate to hang prior to tightening down.
3
Attach the chosen controller to the mount plate. Note the notched screw hole for easy pre-mounting.
5
6
Plug the accessory wires into the controller ports. Plenty of room for hand movement.
If needed the multiplier is easily notch-mounted and then secured on top with a screw.
7
8
9
Several built-in zip tie locations provide wire management and effective strain relief to a variety of configurations.
Tabs on the top of the lid allow it to hang and pivot down into place. This simplifies assembly and reduces fasteners.
>
controller fit test
First, hand start the mounting screws to the back side of the electronics box mounting plate.
2
Slide the assembly to the right behind the screw. This keeps the controller in place prior to tightening.
Pride Mobility Products - Tru Comfort Seat Back - 2011
Two screws at the bottom finish off the electronics box assembly.
Chris Terella - Industrial Designer - cterella@gmail.com
Validation. user observation >
To gain validity on the electronic box design we returned to the production facility in Duryea, PA to conduct user testing. Here we encouraged the assembly staff to test out the new design. During the process we observed their tendencies and took note of their suggestions for further refinement. By examining the new design from the assembly worker’s perspective we were able to identify new opportunities and integrate timesaving considerations into the final design.
>
SolidWorks E- Box
A mobile test dummy has been constructed for off-site testing of the electronics box.
The same employee that offered valuable input during the research phase now has the opportunity to validate the new design.
The notched multiplier mount is a welcomed feature.
Pride Mobility Products - Tru Comfort Seat Back - 2011
Mounting the multiplier at an angle leaves room to tuck wires behind it.
Power cord management is unrestricted and open.
Setting the stage with a brief introduction.
Final packing of the wires.
Set up and ready for testing in Duryea assembly location.
This worker threads a zip tie through the provided mount location.
Hanging the lid to complete the install appears to be intuitive.
Chris Terella - Industrial Designer - cterella@gmail.com
E-Box.
zip tie point
features >
The new Tru Comfort electronics box simplifies the assembly process, accepts more controllers, enables good wire management, contains service friendly features, and maintains a small foot print.
universal Controller mount (steel)
hang tab
tester/manual override kit
multiplier mount (steel) AAM controller
power accessory cords
extra zip tie
accessory multiplier
e box base (ABS)
wire hook
snap tabs
zip tie
Research + Understanding = Informed Solutions
This zip tie detail incorporates visuals for quick identification and two-way securement.
Pride Mobility Products - Tru Comfort Seat Back - 2011
The angled multiplier mount enables accessory wire attachment and detachment without controller removal.
A loose seat plug spells problems for a power chair user. Utilizing zip tie locations can ensure effective strain relief.
Chris Terella - Industrial Designer - cterella@gmail.com
Renderings. presentation >
Historically, most seating systems held no visual relationship to the power base they were attached to. The two components seemed disconnected and treated as separate entities. Although functionally this may be an acceptable approach, aesthetically it’s less than desirable. A power wheel chair is viewed by its owner and the general public as a single entity. For this reason a strong emphasis was placed on visual integration and coherency to the Quantum design language. This can clearly be observed in the completed power chair renderings.
> >
visual continuity
Pride Mobility Products - Tru Comfort Seat Back - 2011
Chris Terella - Industrial Designer - cterella@gmail.com
Color Options. choices >
People have strong opinions when it comes to color selection. Some prefer a bright bold look while others opt for a more subtle approach. Either way – having color options available creates a more personalized feel to the product. For years Pride has offered its power chairs in a host of colors. Additionally color is now offered in the new Tru Comfort seat back. Because the seat back is located close to eye level, painting it a color can have a visually profound effect. Many people like color matching the seat and base for integration, but some do not care for the added visual interest. For these folks a black on black seat back is always an available option.
Pride Mobility Products - Tru Comfort Seat Back - 2011
Chris Terella - Industrial Designer - cterella@gmail.com
China.
manufacturing > China was selected as the manufacturing location for the Tru Comfort plastics. The process begins when the vendor receives the part models and begins cutting the tool. Once complete these tools are used in the injection molding machines to produce the plastic parts.
Injection molding tool for the 18 inch high seat back set.
The seat back tool mounted within the injection molding machine.
A factory worker reviews the first shots from this tool.
Hot off the press - one complete plastic seat back set.
first article > Reviewing all the first shot plastic parts can be a lengthy process. Each part is inspected closely for defects, tooling errors, part damage, and tolerance issues. Any concerns are highlighted and documented for later review with the manufacturing vendor.
Each part is reviewed for consistency and error detection. Often these first shots are used later on functional prototypes or for testing.
Pride Mobility Products - Tru Comfort Seat Back - 2011
Having all the necessary plastic parts in hand allows us to test-fit and assemble the full seat back.
Each issue is identified with a white marker and photographed for the vendor to review.
Chris Terella - Industrial Designer - cterella@gmail.com
The Results. then and now >
It is easy to see why the original Tru Comfort seat back was a success with its simple clean design. The new Tru Comfort strives to build o the original by establishing a visual unity between the seat and base. This is achieved through color and form integration. A host of sizes are now available thanks to the modular expandable subcomponents.
Bryan Anderson > Bryan is the National Spokesman for Quantum Rehab, a division of Pride Mobility Corp. He travels the country making numerous personal appearances while delivering his message of perseverance and determination in major rehab facilities. Bryan is an energetic and enthusiastic individual who enjoys challenging his limits. He skateboards, snowboards, wake boards, white water rafts, and rock climbs. He loves to travel and enjoys meeting new people.
Pride Mobility Products - Tru Comfort Seat Back - 2011
Chris Terella - Industrial Designer - cterella@gmail.com