Advanced Material + Processes: Telepresence Robots

process book advanced materials + processes 2018

TELEPRESENCE ROBOT

ELAINE LUMANAUW

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PROJECT redesigning a telepresence robot for a specific target audience through detailed material processes.

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A BRIEF EXPLANATION about the robot history, uncanny valley, and a brief background in regards to telepresence robots.

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WHAT IS: TELEPRESENCE ROBOT A

telepresence

robot

is

a

remote-controlled,

wheeled device that has wireless internet connectivity. Telepresence robots have often been referred to as “skype on wheels.� However, telepresence ro bots (also known as virtual presence robots or remote presence robots) are much more. For example, instead of having a static view of participants (as with skype and other video conferencing applications), the controller of the robot is able to con-

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trol what they wish to see, as opposed to needing someone to point a camera at a particular person.

Many telepresence robots come equipped with such features as laser pointers, zoom capabilities, and autonomous driving for enhanced communication as well as convenience.

CURRENT ROBOTS

These are the current robots available in the market.

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1950 1972 1986 199

Alan turing publishes paper about possibilities that machines could think

SCARA, an articulated robot arm, is developed for assembly lines

Honda creates the first series of humanoid robot that walk on two feet

NASA’s pathfinder lands on

william grey creates first autonomous robot

george devol invents first digitally programmable robot

Jaron Larier (VPL) research sells first VR glasses and gloves

The first phrase AUGMENTED REALITY was founded

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1921

the first ever robot was used by a czech writer

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ROBOT HISTO

1948 1954 1985 1990

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2007 2013

Fenuc developes robot arm

Google launches Google glass, augmented reality glasses

Google introduces 3D street view maps

2010 Drone industries are predicted to make 127billion dollars

Alexa has been launched - a virtual assistant to help home duties

UN estimates there are a lot of robots used worldwide (742K)

2000

Sony playstation launches playstation VR -Uber starts inventing driveless cars

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Mars

ORY TIMELINE

2015 2020

2016

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OBSERVATION

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GARTNER G artner, Inc. is an American research and advisory firm, providing IT related information given to companies all over the world. (Wikipedia)

G artner ’s function as written: “helps business leaders in every industry and enterprise with the objective insights they need to make the right decisions.” G artner is headquartered in Stamford, Connecticut, USA, G artner has more than 15,000 associates serving clients in 11,000 enterprises in 100 countries. (G artner.com)

Based on G artner ’s most current hype cycle of emerging technologies (2017), Telepresence robots are not anywhere near the chart. However, in 2009’s chart, Video telepresence are right where ‘Peak of inflated expectations’ are.

OBSERVATION

UNCANNY VALLEY The “uncanny valley” is a human character (or an emotional response) that happens when someone encounters something that is almost (but not really) human.

It all started in 1970. A Japanese robot-expert Masahiro Mori, made a claim that as robots were built to be more human-like, people would find them being a lot more acceptable and appealing, disregarding their mechanical counterparts. But turns out that this claim was false. As they were built closer and closer to look like humans, people became uneasy and experienced discomfort.With the increasing quality in virtual reality, augmented reality, and computer animation, the ‘valley’ has been cited in the popular press in reaction to the effect of creation as it creates indistinguishability from reality.

Reference: h t t p s : // w w w. t h e g u a r d i a n . c o m /c o m m e n t i s f r e e / 2 0 1 5 / n o v/ 1 3 / r o b o t s human-uncanny-valley https://www.wired.com/story/future-of-artificial-intelligence-2018/

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OBSERVATION

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WIRELESS POWER +CHARGING Some ideas from existing tech to support my redesigne robot.

TYPES OF WIRELESS CHARGING Inductive, surface contact - utilizes an electromagnetic field to transfer energy between two objects through electromagnetic induction.

Resonance, mid-range charging - has relatively low efficiency due to flux leakage even when the device is placed closer to the wireless charger.

Radio wave, long-range charging - the concept of long range charging consists of utilizing different technologies such as, radio frequencies, infrared light, and ultrasound.

ISSUES Resonance and radio wave offer slower charging speeds, does not have enough capacity to charge larger devices like phones yet, and if any object blocks path of charging, device will not be charged.

COMPANIES + PRODUCTS Avido, Pi, Qualcomm Halo, Wibotics, uBeam, Powercast, etc.

PROS AND CONS OF TELEPRESENCE WIRELESS CHARGING Pros : “park and forget �, no need a USB port and wireless would remove strain on cable, and inductive contact charges as fast (if not faster than traditional cable plugs.

Const : added costs for adaptive charging solutions, no standard set for wireless charging tech, heat transfer and cooling issues.

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FIELD RESEARCH We did a field research in one of the tech museums in Mountain View called the Computer History Museum. They are one of the many museums out here that have telepresence robots available to aid people who cannot view the museums in person.

We spoke to one of the people who was in charge of dealing with telepresence robots, and she explained quite a lot in regards to how this works, how it benefits the museum, as well as its drawbacks.

We did a couple of test runs through the museum and noticed in more detail how these robots actually function to get a better understanding and knowledge in regards to redesigning a telepresence robot.

COMPUTER MUSEUM HISTORY Mountain View, CA

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FIELD RESEARCH: MATERIALS We went to art 207 to observe many materials from “Connexion”. I was honestly really intrigued and interested because of the many materials there were on the wall. From plastic, to very random materials (like broccoli, I think) were posted – and that is only some out of the many materials they have.

The second picture (I forgot what it was called) really caught my eye because of the many colors it had and it showed such vibrancy. Just by looking at it, I thought it was soft and silky. But when I touched it, little did I know that its

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texture was very rough-like. It was not as soft as it seemed to be.

The first picture of wood textures got me really interested because it had the very clean and rigid feel to it, which I would probably use for my final rendering model for telepresence robot. The rest were interesting as well, but it did not really catch my eye or attention.

MATERIAL CONNEXION SAMPLE TOUR San Jose State University, CA

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RESEARCH During one of the class times, Professor gave a demo on driving a telepresence robot from BEAM. We actually got to drive an actual BEAM robot located in Texas.

There were many notes in regards to how this works, but this was a good experience.

BEAM PROGRAM San Jose State University, CA

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REFERENCE ROBOT This is the robot I will be using for reference towards my newly redesigned robot. My redesign robot ’s components will have the same components as this one.

ORTHOGRAPHICS + DETAILS

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TARGET MARKET + FOCUS I want my redesigned telepresence robot to aim for child or kids use, in a modern housing environment. I would imagine their parents going away for a business trip - therefore this robot will be a perfect tool to check up on their children.

Since my main focus will be to redesign for children use, I would like my telepresence robot to mainly focus on these things:

have a friendly feel - no sharp edges, appealing and interesting for children to use, non intimidating

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look clean - simple yet eye-catching playful - a robot that is not too rugged, aiming for attracting children a tint of vibrant - a use of light colors interactive - features that attract children

courtesy of Google.com

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SKETCHES

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MANUFACTURING This part explains all the manufacturing processes, possible manufacturers, rules in manufacturing and things to consider.

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MANUFACTURING CONCEPTS

SHEET METAL FORMED Force is applied to a piece of sheet metal to modify its geometry. The applied force stresses the metal beyond its yield strength, causing the material to deform but not to fail. By doing this, the sheet can be bent or stretched into a variety of complex shapes. There are a couple of processes included in the sheet metal forming, like bending or roll-forming.

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MANUFACTURING CONCEPTS

SUBTRACTIVE ETCHING (the image shows small amount of etching). Etching is a traditional process of using strong acid or mordant to cut into parts of metal surfaces, to create a design in incised in the metal.

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MANUFACTURING CONCEPTS

ADDITIVE ROTATION MOLDING Also called rotomolding or rotocast, is a thermoplastic process for producing hollow parts by placing powder or liquid resin into a hollow mold and then rotating the tool bi-axially in an oven until the resin melts and coats inside of the mold cavity.

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MANUFACTURING CONCEPTS

SAND CASTING The process of sand casting consists of a metal casting tool or process, using sand as its mold material. Molds made of sand are relativelty cheap, and in addition to the sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand.

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MANUFACTURING CONCEPTS

3D PRINTED the process is mainly to synthisize a three dimensional object controlled under a computer to create an object.

One of the many advantages would be that the objects can be almost any shape or geometry. It is produced from

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digital modeling applications or 3D model applications, as well as many other data sources.

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MY SELECTION + WHY

3D printed, subtractive/etching, rotation molding, casting, sheet metal.

I chose the rotation molded process because of the very friendly feel and look to it. With colors added onto it, This will look more vibrant and playful.

EXPLODED VIEW + REFINEMENTS

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MANUFACTURING PROCESS IN DEPTH

SCREEN HOUSING Vacuum Casting Visual quality Speed Mold cost Unit cost Sustainability

Laser Cutting Visual quality Speed Mold cost Unit cost Sustainability

Reaction Injection Molding Visual quality Speed Mold cost Unit cost Sustainability

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BODY Injection Molding Visual quality Speed Mold cost Unit cost Sustainability

Reaction Injection Molding Visual quality Speed Mold cost Unit cost Sustainability

Rotation Molding Visual quality Speed Mold cost Unit cost Sustainability

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CHOOSING MANUFACTURERS In order to create a very good quality product, picking the right manufacturers for each part is very important.

-

Here are some of the criteria one may take into consideration before listing out manufacturers.

WHO YOU ALREADY KNOW One to take into consideration are the manufacturers and the people you’ve worked with and/or have visited. Good past work experience with the people may do you good in creating future products (they may help in saving money as well, because of the built relationships with them). :) RECOMMENDATIONS Recommendations from other peers or people you know may be a suitable op tion. Sometimes people you know or your past experience may come in handy when dealing with material selection criterias.

TRADE SHOWS Trade shows may be the quickest way to look for a manufacturer, because they are all gathered in one spot. Through trade shows, you can easily build relation ships, exchange contact numbers, and perhaps find the right manufacturers.

MANUFACTURERS’ REPRESENTATIVES Manufacturers’ Reps are a good thing because their goal is to make themselves wellknown amongst businesses. They have a huge array of options, which gives you leverage towards freedom in choosing the right manufacturer (because they are free!).

RESEARCH Probably the most vague and broadest way to look for manufacturers (but crucial, too). Searching through the web gives you endless choises in picking the perfect manufacturer. But be careful, though. The internet can be dangerous and there are many manufacturers who fake their quality.

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SCREEN HOUSING

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LASER CUTTING MANUFACTURERS

Precision Metal Works

“Precision Metal Works provide the quality service with friendly

Campbell, CA

support for prototype, light production, aluminum spot welding, and machining. No job is big or too small for us.”

Advanced Laser

“Advanced Laser & Waterjet Cutting provides precision cutting

& Waterjet Cutting

services of a variety of materials. In addition to quick turn-around

Santa Clara, CA

time we offer CAD design and can help with reverse engineering of parts. Please contact us today for your free estimate.”

Hopeland

“Hope land laser cutting values all customers and want to build

He Bei, CN

long-term cooperation with you. No matter you are individual or company, we do 100% works to promote your jobs/projects finished perfectly.”

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BODYPARTS + NECK

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ROTATION MOLDING MANUFACTUERS

Sherman Tank

Sherman Roto Tank LLC maintains its industry reputation as

Rotomolding Services

a market leader and is committed to providing products that

Peerland, TX, US

accommodate your business needs through reliable products, quality manufacturing practices and dependable solutions.

RMI Inc.,

In the world of rotational molding, one company stands out,

Gardena, CA, US

Rotational Molding Inc. – a leader with experience and capabilities to manufacture high quality, proprietary, and custom rotationally molded products for almost any application, including industrial, pharmaceutical, aerospace, agricultural, and recreation. For over 3 decades, rotational molding in G ardena, CA has been bringing solutions to the manufacturing industry through this process.

Today rotational molding is considered to be one of the fastest growing plastics processes in the world.

Hopeland

The purpose of Ningbo Jinhong Rotation Mold Co, Ltd. is

He Bei, CN

“Quality oriented, customer comes first and credibility of the first ”, offering customers the topping servation, and putting more efforts into the whole process of design, manufacture and use.”

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Screen Housing

Machining

Nylon

Body, neck

Roto molding

Plastic

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CONCLUSION

Screen housing | Laser Cutting Precision Metal Works, Campbell, CA, US

The visual quality is outstanding, with speed not being a prominent feature because it would be fine - it would be a medium to low volume product. Cost is not something to be concerned about because it is not under my adjectives.

Percision Metal Works’ products’ visual quality is outstanding, with speed not being a prominent feature because it would be fine - it would be a medium to low volume product. Cost is not something to be concerned about. There were good reviews as well for this company.

Body and neck | Rotation Molding RMI Inc., Gardena, CA, US

I need these parts to have a good visual quality. Cost is cheaper but it is rea sonable for these parts. This process works best for roundish and soft shapes.

We can also get rid of parting lines through secondary ops.

I chose RMI, inc. mostly because they are US based as well (as AEMT). With this, the production line can hinder shipping cost - especially when dealing with high quantity rates. In addition to that, they are on the more cheaper side with rather good quality.

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FASTENING AND JOINING Fastening and joining is a method to ‘combine’ two objects together. There are many processes in undergoing fastening and joining, but using the right fasteners and the right process is crucial in this step.

Fasteners are main components used in many sectors e.g.automation, etc with different types of items are produced that require assembly of machenery parts.

A fastener can be a special type of nail that has spirals on its side. Some of the

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most common fasteners include bolts, nuts, bars, screws, rivets, etc.

Innovative designs and better materials combine in fasteners that are strong, durable, and look good. The resulting systems provide a welcome balance between aesthetics and function.

These are examples of guidelines on which fastener to use.

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DFMA Design for Manufacturing (DFM) and design for assembly (DFA) are the integration of product

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design, and process planning into one common activity. The goal is to design a product that is easily and economically manufactured. The rules are as follows.

01

Reduce the total number of parts.

It reduces the level of intensity of all activities related to the product during its entire life. Some approaches to part-count reduction are based on the use of one-piece structures and selection of manufacturing processes.

02

Develop a modular design.

Modules add versatility to product update in the redesign process, help run tests before the final assembly is put together, and allow the use of standard components to minimize product variations.

03

The use of standard components The use of standard components refers to the production pressure to the supplier, relieving in part the manufacture’s concern of meeting production schedules. They’re less expensive, too.

04

Design parts to be multifunctional.

They reduce the total number of parts in adesign, thus, obtaining the benefits (rule 1). Additionally, there can be elements that besides their principal function have guiding, aligning, or self-fixturing featuresto facilitate assembly, and/or reflective surfaces to facilitate inspection, etc.

05

Design parts to be multi-use.

In a manufacturing firm, different products can share parts that have beendesigned for multi-use. It is necessary to identify the parts that are suitable for multi-use.

06

Design for ease of fabrication Modules add versatility to product update in the redesign process, help run tests before the final assembly is put together, and allow the use of stan dard components to minimize product variations.

07

Avoid seperate fasteners.

The use of fasteners increases the cost of manufacturing a part due to the handling and feeding operations that have to be performed. They also contribute to reducing the manufacturing efficiency.

08

Design parts to be multifunctional.

They reduce the total number of parts in adesign, thus, obtaining the benefits. Additionally, there can be elements that besides their principal function have guiding, aligning, or self-fixturing featuresto facilitate assembly, and/or reflective surfaces to facilitate inspection, etc.

09

Design parts to be multi-use.

Errors can occur during insertion operations due to variations in part dimensions or on the accuracy of the positioning device used. For this reason, it is necessary to include compliance in the part design and in the assembly.

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Design for ease of fabrication Handling consists of positioning, orienting, and fixing a part or component.

To facilitate orientation, symmetrical parts should be used when ever pos sible. Use external guiding features to help the orientation of a part. The subsequent operations should be designed so that the orientation of the part is maintained.

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REGULATORY AGENCIES A

regulatory

agency

(also

regulatory

authority,

regulatory

body or regulator) is a public authority or government agency responsible for exercising autonomous authority over some area of human activity in a regulatory or supervisory capacity. An independent regulatory agency is a regulatory agency that is independent from other branches or arms of the government.

Regulatory agencies deal in the areas of administrative law, regulatory law, secondary legislation, and rulemaking (codifying and enforcing rules and regulations and imposing supervision or oversight for the benefit of the public at large).

The FDA is responsible for protecting and promoting public health through the

control

and

supervision

supplements,medications,

of

vaccines,

food

safety,

tobacco

biopharmaceuticals,

products, blood

dietary

transfusions,

The stated mission of the Environmental Protection Agency is to “protect human health and the environment.” So they ensure that the living and working environments of those living in the US do not pose a significant risk to our health.

The National Science Foundation (NSF) is a United States government agency that supports fundamental research and education in all the non-medical fields of science and engineering.

CE Markings on products is a manufacturer ’s declaration that the product complies with the essential requirements of the relevant European health and safety.

UL Listing means that UL has tested representative samples of a product and determined that it meets UL’s requirements. These requirements are often based on UL’s published and nationally recognized Standards for Safety.

The stated mission of the Environmental Protection Agency is to “protect human health and the environment.” So they ensure that the living and working environments of those living in the US do not pose a significant risk to our health.

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OKALA DESIGN STRATEGY GUIDE This is another thing to consider when redesinging my robot.

“

The Okala Ecodesign Strategy Wheel clusters strategies according to the stages of the life-cycle of the product. Designers can use many of these strategies, or focus on a few. The wheel serves as a powerful brainstorming

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tool

to

explore areas

of

product

development

have not yet been considered.

or

improvement that

1. Innovation Rethink how to provide the benefit. Design flexibility for technological change.

Provide product as service. Serve needs provided by associated products. Share among multiple users. Mimic biological systems. Use living organisms in product systems. Create oppurtunity for local supply chain. I choose to design my product as service, with the goal of helping others in need.

2. Reduced material impacts Avoid materials that damage human or ecological health. Avoid materials that deplete natural resources. Minimize quantity of material. Use recycled or reclaimed materials. Use renewable resources. Use material from reliable certifiers. I will minimize quantity of materials, which will also help me in creating a more lightweight product.

3. manufacturing innovation Minimize manufacturing waste. Design for production quality control. Minimize energy use in production. Use carbon-natural or renewable energy resources.

Minimize number of production steps. Minimize number of components/materials.

Seek to eliminate toxic emissions. I choose to minimize number of components/ materials. An advantage for this is fewer parts may be easier to assemble.

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4. Reduced distribution impacts Reduce product and packaging weight. Reduce product and packaging volume. Develop reusable packaging systems. Use lowest-impact transport system.

Source or use local materials and production. I choose develop reusable packaging systems and reduce the volume of my product.

5. Reduced behavior and use impacts Design to encourage low-consumption user behavir. Reduce energy consumption during use. Reduce material consumption during use. Reduce water consumption during use. Seek to eliminate toxic emissions during use. Design for carbon-neutral or renewable energy. I will seek to eliminate toxic emissions during use.

6. System longevity Design for durability. Design for maintanence and easy repair. Design for re-use and exchange of products. Create a timeless aesthetic. Foster emotional connection to product. I will create a timeless aesthetic to it.

7. Transitional systems Design upgradeable products. Design for second life with different function. Design for reuse of components. I choose to design upgradable products.

8. Optimized end of life Integrate methods for used product collection. Design for fast manual or auto mated dissasembly. Design recycling business model. Use recyclable non-toxic materials. Provide ability to biodegrade. Design for safe disposal. I choose to create a design for fast manual or automated disassembly. Since I will be less ening my parts for my product, this would be a rather easy step for me to do.

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BRANDING A list of possible branding methods.

PRINTED

INTEGRATED

APPLIED

OTHER

airbrushed

laser etching

sticker

sandblast

hand painted

embossed

decal

resin dye

hydro printing

machining

plated

inlay

UV printing

3D printing

cast plate

backlit

stamping

laser cutting

injected mold plate

pad printed

electroforming wood burning tag

position of branding

PAD PRINTED Pad printing is such an easy and cheap way to get away with a good looking logo. If done well, the paint won’t chip and it will look good, but it still does not look as good to my liking.

BACKLIT This is an interesting way of showing the brand - placing light behind the logo to further emphasize the brand. One drawback is that this will increase the total cost and is a very tideous method of branding.

LASER CUTTING Laser cutting the plastic along with the rest of the piece is a very simple and cheap way of branding. I would go with this method because it is a very time efficient process.

STICKER/DECAL Printing stickers and sticking it on the product would be a very time efficient and easy way to portray the brand, but the drawback would that this sticker can peel off easily and hence the product will eventually lose its logo.1

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FUTURE ROBOT CONCEPT In this section, I experimented with a design concept and the features for a telepresence robot that could actually be built in the upcoming years.

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After further research, I preferrably have found some changes that

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would improve the abilities of current telepresence robots. The current telepresence robots in the markets are great already, but would not it be just wonderful to add various technologies to it, to improve the quality of telepresence robots?

FEATURES SOLAR POWER I would propose to put in this feature of the telepresence robot ’s power source to minimize running cost. The initial cost is already expensive enough and it would really be an advantage for a telepresence robot to have a cheap running cost. A little bit about solar power: First, sunlight hits a solar panel on the roof. The panels convert the energy to DC current, which flows to an inverter. The inverter converts the electricity from DC to AC, which then can be used as power! 2025 would be a proximate year for solar power ’s ability to charge telepresence robots

AUGMENTED REALITY This would be more for the user. Augmented reality (AR) is a direct or indirect live view of a physical, real-world environment whose elements are

“augmented”

by

computer-generated

perceptual

information,

ideally across multiple sensory modalities, including visual, auditory, haptic,

somatosensory,

and

olfactory.

(https://en.wikipedia.org/wiki/

Augmented_reality). This would be a helpful tool for the user (who directs the robot) for a more user friendly experience. Instead of having to coordinate hand and eye using keyboards, the user can just have a huge screen and press on it for the robot ’s movements. E.g. to pick up an item using its loading/unloading feature, the user just needs to press on the ‘object ’ shown on the screen, and then the robot can pick it up. It ’s more simple. In a couple of years, like in 2023, this would be available.

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LEVITATION Or acoustic levitation, is a technology process where an object has an ability to move through space without even touching the ground. In a more recent study, researchers have experimentally demonstrated the acoustic levitation of a 50-mm (2-inch) solid polystyrene sphere using ultrasound—acoustic waves that are above the frequency of human hearing. It works by utilizing standing sound waves and right now, researchers have managed to create fixed levitating [smaller] objects so this technology would probably be available to use in the year of 2030 at the least. “At the moment, we can only levitate the object at a fixed position in space,” Andrade said. “In future work, we would like to develop new devices capable of levitating and manipulating large objects in air.”

( h t t p s : // p h y s . o r g / n e w s / 2 0 1 6 - 0 8 - a c o u s t i c - l e v i t a t i o n - l a r g e - s p h e r e . html#jCp)

ORTHOGRAPHICS

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DETAILS

21 MP camera for a really good quality display for the back end, might as well

This d isplay i s for the front end u sers t o view the back end users.

This part is basically solar panels planted inside of t he body, for solar charging. This is a really unique and strong feature, t o decrease running costs because t he i nitial costs are already high.

If t he r obot i sn’t l evitating, it will roll - walk using this giant wheel. ‘hogging o ut’ on t he w heels to lighten t he robot.

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COLOR, MATERIAL, FINISH Going back to my robot. :) almost-to-last final touches.

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MATERIAL SELECTION

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SCREEN HOUSING

Nylon, Nylene 494 Durability Aesthetics Material cost Sustainability Impact strength

TPE, Hytrel Durability Aesthetics Material cost Sustainability Impact strength

Bakelite, thermostat polyester Durability Aesthetics Material cost Sustainability Impact strength

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NECK + BODY

Polyutherane, Bayflex Durability Aesthetics Material cost Sustainability Impact strength

EVA Copolymers Durability Aesthetics Material cost Sustainability Impact strength

Inorganic glass fiber Durability Aesthetics Material cost Sustainability Impact strength

PP RR OO CC EE SS OO OO K S SBB K

additional rubber

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CONCLUSION I chose nylon because it is durable yet has a very appeal ing look. It is safe for children (safer compared to metal or the other hard and brittle materials), and although it is not sustainable, it has very high impact strength.

TPE works well because it is said to be the most aesthetically pleasing material. Another good feature of this is how it is sustainable.

Additionally, I wanted to add rubber to some parts of my robot (shown on the left).

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COLOR SELECTION

After the materials, the colors were then my next consideration.

01

02

03

01: Screen housing

dark colors (e.g. black), white, colorful (e.g. blue) I choose white-greyish for my telepresence robot because it has a light feel to it. Black is too absorbing, other colors look ‘cheap’.

02: Body

dark colors (e.g. black), white, colorful (e.g. blue) White would look great in complimenting the white screen housing. Black and bright colors do not really have a good feel to it.

03: Highlights on robot (and rubber)

dark colors (e.g. black), white, colorful (e.g. blue) The bright colors would look perfect for this. It brings out the playfulness of the robot. Blue would be the default color of my robot, though.

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FINISH

Last touches - how the material would look.

01: satin

finish

02: high gloss

finish

03:rubber

placement

01 semi-gloss finish, textured finish, high gloss finish Semi-gloss finish would be great for the screen housing.

Texture would be too rugged and metallic would have a manufactured feel to it.

02 semi-gloss finish, textured finish, high gloss finish I would like high gloss finish for the white parts of my telepresence robot as well, to complement the screen housing.

03 textured finish, satin finish, polished finish Polished finish would be great for this to bring out the vibrant look of it, and not be overshadowed by the rest of the rest of the materials and finishes.

PROCESS

B O O K

ADVANCED MATERIAL & PROCESSES, DSID 143

1

2 3 1

2 3

84

RECAP + LIST

01

Screen housing The color I have chosen for this is Polished White Alyssum (PAN TONE 11-1001 TPX). The finish would be using spray paint, semigloss.

02

Neck + Body I matched this to the screen housing so I used polished White Alyssum (PANTONE 11-1001 TPX). The finish would also be using spray paint, semi-gloss.

03

Highlights on robot + rubber My default color for the highlights would be Island Paradise (PANTONE 14-4620). This is the perfect color because it is bright and playful. The rubber as well would be that particular color.

Rubber can be spray painted and the highlights will be brushed.

Color alternatives: Barely Pink (PANTONE 12-2906), Warm Gray (PANTONE 1C), Spa Blue (PANTONE 13-6107), Gray Lilac (PANTONE 13-3804).

PROCESS

B O O K

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86

COSTED BOM

1

2

3

3

3

4

Tooling cost $ 1

Laser cutting

0

2

Rotation molding

10 000

3

Rotation molding

20 000

4

Rotation molding

6 000

36 000 Part cost $ 1

Nylon

1 090

2-4

Polyutherane

10 000

4

Rubber *

100

11 190 Possible labor work

Assembly 17/hr *6 102

$46 192/unit

It costs $46,192 for one unit to be produced when tooling, part, and la bor costs are taken into account. The next objective is to find out how many units exaclty can be mass produced, to save on tooling costs.

*Rubber = second op material

88

COMPARISON 1K

10K

36000

3600

360

36

3.6

.36

.036

Part Cost

11 190

11 190

11 190

11 190

11 190

11 190

11 190

Labor Cost

102

102

102

102

102

102

102

11,652.00

11,328.00

11,295.60

11,292.36

11,292.036

ADVANCED MATERIAL & PROCESSES, DSID 143 B O O K PROCESS

Cost/unit

14,892.00

100

Tooling Cost

1

47,292.00

10

Units

GRAPH COST/UNIT

100K

1

CONCLUSION Firstly, I broke down 3 major aspects to consider for pricing - Part cost, material cost, and labor cost. The part costs were the ones that alters based on different quantities of units being produced, while material and labor cost stay the same.

The price drastically got lower once it had more units being produced, but once it got into 1000 units and over, the pricings have reached a plateau making 1000 units at a price of $11,328.00 per unit become the sweet spot.

In addition to that, I have chosen rotation molding as my manufacturing process because it is suitable for low volume production and laser cutting because I do not have to pay for tooling cost.

Seeing this data, I would conclude that could sell this robot for around $19,000, with around $7,700 as my margin. If all 1000 pieces are sold with a 1% defact, I could still earn $6,930,000.

PROCESS

B O O K

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FINAL DESIGNS

P R O C E S S B O O K P R O C E S S B O O K

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PRP O RC O EC SS E SB S O BOOK O K

ADVANCED ADVANCED MATERIAL MATERIAL & PROCESSES, & PROCESSES, DSID DSID 143 143

94 94

P R O C E S S B O O K ADVANCED MATERIAL & PROCESSES, DSID 143

P R O C E S S B O O K ADVANCED MATERIAL & PROCESSES, DSID 143

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PRP O RC O EC SS E SB S O BOOK O K

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THANK YOU

100

GLOSSARY Arm

A mechanical programmable arm that has similar functions to the human arm.

Artificial Intelligence

ADVANCED MATERIAL & PROCESSES, DSID 143

Computer systems being able to do specific tasks that require human intelligence e.g. speech, visual, etc.

Autonomous robot machines that can perform tasks without too much of human control.

Contact sensor An object that is affected by a transducer.

Controller [system] A control system regulates other devices or systems using control loops.

Encoder A device, circuit, transducer, software program, algorithm or person that translates a piece of information from one format or code to another.

End-effector A device or tool that ’s connected to the end of a robot arm where the hand would be.

Force sensor A transducer that converts a mechanical force into an electrical force.

Intelligent robot A robot functioning as an intelligent machine that can be programmed to take actions or make choices based on sensors.

Interface A boundary between different matters/physical states.

Motor A machine that converts electrical energy to mechanical energy.

Optical sensor

PROCESS

B O O K

Electronic detectors that convert light into an electronic signal.

Proximity sensor An object that emits a beam of electromagnetic radiation (infrared, for instance), and looks for changes in the field or return signal.

Robot A manmade object capable of carrying out a complex series of actions automatically.

Sensor A device to detect changes in its environment and send the information to other electronics, frequently a computer processor.

Sensors A series of device to detect changes in outer environment.

Servo motor An actuator that allows control of velocity and acceleration.

Uncanny valley A relationship between an object ’s resemblance to a human being and the emotional response to such an object.