Telepresence Robot Process Book Huiying Tan
CONTENTS TELEPRESENCE ROBOT DEFINITION
HIGH VOLUME DESIGN
PERSONA
HIGH VOLUME PROCESS
MARKET RESEARCH
DESIGN COMPARISON
HISTORY
DFMA
INTERNAL COMPONENTS
SUSTAINABILITY
IDEATION
MATERIALS
LOW VOLUME IDEATION
MANUFACTURERS
LOW VOLUME DESIGN
BRANDING
LOW VOLUME PROCESSES
COLOR, MATERIAL, FINISH RENDER
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THE PROBLEM Current Telepresence Robot designs on market overlook the functions and aesthetics for the home environment.
SOLUTION Design a telepresence robot fits into home environment, while incorporating functions that help and enhance daily life.
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WHAT IS A ROBOT? A robot is a programmable, multi-functional manipulator designed to move material, parts, tools, or specialized devices through variable programmed motions for the performance of variety of task.
WHAT IS TELEPRESENCE? Telepresence is a sophisticated form of robotic remote control in which a human operator has a sense of being on location so that the experience resembles virtual reality (VR). The remotely- controlled robot and the human operator can be located at a great distance from each other. Control and feedback are done by telemetry over wires, optical fibers, wireless links or the Internet.
WHAT IS A TELEPRESENCE ROBOT? A telepresence robot is a computer, tablet, or smart phone-controlled robot which includes a video-camera, screen, speakers and microphones so that people interacting with the robot can view and hear its operator and the operator can simultaneously view what the robot is “looking� at.
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A BRIEF HISTORY OF
Telepresence
1970 AT&T Picture Phone
1996 NetMeeting
1992 AT&T VideoPhone Huiying Tan 6
2001 Teliris deploys the 2nd telepresence GlobalTable
2006 Cisco CTS3000
2009 Apple FaceTime
2005 Telanetix ships first Digital Presence System
2006 Skype Video
2017 TODAY
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Market Research Telepresence robot device markets at $825 million in 2015 are anticipated to reach $7 billion by 2022 as next generation robotic devices, systems, and instruments are introduced to manage remote presence. The robotic platform will be extended to include grippers and cameras of all types, sensors and sophisticated navigation software.
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Beam Robot $9700 34-74” Custom 2 radio Wifi connectivity, predictive pathvisualization,audio array with echo, powerful speaker for noisy environment
TILR $10000 3’8” OF 4’2” Web-based controls; can use own video like Skype,Google Vid Chat,etc.
VGO $6000 4’0” Text-to-speech;camera auto-tilts based on drive speed;remote monitoring headlights and auto-docking to the charger.
QB $15000 2’6”-6’0” Two-wheel drive design; stabilized video; Web-based controls.
Jazz Connect $2499 40” Fully web-based,double camera for navigation and specific tasks. Orientable Head for fast point of view change and a better interaction.
TeleMe $1650 5” Optional Laser pointer aimed with Pan/Tilt control of Tablet.
Double $2499 47”-59” Self-balancing robot will remain upright even if bumped into by people or things. Very light 9 Huiying Tan
PERSONA I International Music Producer Wants a larger presence at home to communicate with clients and musicians.
LOW VOLUME / EXPENSIVE
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PERSONA II Music Therapist Wants to provide music therapy with patients at home.
HIGH VOLUME / INEXPENSIVE
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Gartner’s Hype Cycle
Gartner’s 2016 Hype Cycle showed a lot of various technology. I predit Telepresence Robot would be under or over smart robots. I think that telepresence robot would be at this spot because it is an emerging other tech into telepresence robot.
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Future of Telepresence Robots
In the future, I believe Telepresence Robots will apply to some fields, such as education, business, hospital, warehouse and shopping mall.
Uncanny Valley Uncanny Valley “ used in reference to the phenomenon whereby a computer-generated figure or humanoid robot bearing a nearidentical resemblance to a human being arouses a sense of unease or revulsion in the person viewing it.�
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Inspiration
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Ideation
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Ideation
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Low Volume Design
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Orthographic
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COMPONTENTS NUMBER 1
AMOUNT 2
NAME Upper Speaker Box
PROCESS Sand Casting
2
2
Lower Speaker Box
Sand Casting
3
2
Speaker
RIM
4
3
Stand
Sand Casting
5
1
Upper Box
Sand Casting
6
1
Lower Box
Sand Casting
7
1
OLED Screen
Laser Cut
8
1
Button set
RIM
9
3
Cable Wires
10
1
Battery Pack
11
2
Wheels
12
1
Charging Port
13
1
Audio Chip
14
1
Computer Chip
15
1
Upper Body box
16
1
Lower Body Box
17
28
Fasteners
1 3 4
7
2 9 5 6
8 15 13
14
16
12
10 11
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Low Volume Process Sand Casting is a process that uses a mold made from either metal, wood, or wax to create a negative impression in a special sand that will be the mold for the molten metal. This mold is then filled with a molten metal that is left to cool and solidify. Once the metal has solidified the mold can be hit with a hammer, pipe, or any hard object to crack the sand mold and expose the metal object. I choose sand casting process
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Secondary Process I Sand Casting is a process that uses a mold made from either metal, wood, or wax to create a negative impression in a special sand that will be the mold for the molten metal. This mold is then filled with a molten metal that is left to cool and solidify. Once the metal has solidified the mold can be hit with a hammer, pipe, or any hard object to crack the sand mold and expose the metal object. I choose sand casting process because it provides a greater detail looking.
Sand mold is made creating inside based on an impressed mold of the desired form.
Molten aluminum is poured into the holes, filling the cavities.
Break away the sand mold after the metal has cooled. The sand could be reused for next time.
Finishing the form is important as every sand cast mold has sprue and risers where the aluminum was poured in and risen up.
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Secondary Process II Plastification
Injection
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Injection Molding is a manufacturing process for producing parts by injecting material into a mold. I choose Injection molding because my design contains Packing/Cooling some small components and injection molding will provide great looking for my parts.
Demold/Ejection
Secondary Process III CNC (Computer Numerical Control) is a process used in the manufacturing sector that involves the use of computers to control machine tools. I choose this process for my telepresence base because it allows for precise cuts. CNC for the base would take special tooling since the part is large and requires different size bits. Designing the CNC. The body must be precise for all the components tightly.
CNC cutting would involve many times to change the tools and bits.
Base CNC would have the final holes drilled in to accommodate the sheet metal component housing attachment
Finishing the inside of CNC base and it provides precise slots for c components. 23 Huiying Tan
High Volume Process Injection molding Process:
A hopper holding plastic granules feeds into a heated barrel.The screw moves the molten plastic through the barrel. At the end of the barrel is a nozzle that feeds into the mold.The one half of the mold moves with the machine for access.The molded part is nearly finished, requiring minimal post ops.
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COMPONTENTS NUMBER AMOUNT 1 1
NAME Front Shell
PROCESS Injection Mold
2
1
Back Shell
Injection Mold
3
2
Speaker
RIM
4
3
Speaker Frame Die Casting
5
1
Screen Frame Die Casting
6
1
OLED Screen
7
1
Button set
8
1
Wheels
9
3
Charging Port
10
1
Audio Chip
11
2
Computer Chip
12
12
Fasteners
13
1
Battery Box
7. 4.
3.
1.
2.
12.
Laser Cut
6.
11.
5. 10.
13.
8. 9.
Snap fit
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Orthographic
R11” R17” R25”
34” 20” 13.20”
24” 13.80”
76”
2”
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25”
High Volume Design
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Low Volume Design
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High Volume Design
DFMA-Design for Manufacture and Assembly Purpose:
Design for Manufacture and Assembly is a quantitative method or tool to assist designers in the effectiveness of designs, in relation to ease and efficiency of manufacturing and assembling products.
Differences: Design for Assembly •
Concerned only with reducing product assembly cost - Minimizes number of assembly operations - Individual parts tend to be more complex in design
Similarities: • • •
Both DFM and DFA to reduce material, overhead, and labor cost They both shorten the product development cycle time Both DFM and DFA seek to utilize standards to reduce cost
Design for Manufacturing •
Concerned with reducing overall part production cost - Minimizes complexity of manufacturing operations - Uses common datum features and primary axes
The Benefits of DMFA • • • •
Reduced manufacuring and labor cost Reduction of number of assembly processes Getting product ot market quicker Reduced risk of part failure
Key DFMA Principles
Key DFA Principles
• • • • • • •
• • • • • • • • • •
Minimize Part Count Standardize Parts and Materials Create Modular Assemblies Design for Efficient Joining Minimize Reorientation of parts during Assembly and/ or Machining Simplify and Reduce the number of Manufacturing Operations Specify ‘Acceptable ‘surface’ Finishes for functionality Conclusion The manufacturing and assembly is important in the design phase because this will avoid errors, cost and saving time.
Minimize part count Design parts with self-locating features Design parts with self-fastening features Minimize reorientation of parts during assembly Design parts for retrieval, handling, & insertion Emphasize ‘ Tap-Down’ assemblies Standardize parts ... minimum use of fasteners Encourage modular design Design for a base part to locate other components Design for component symmetry for insertion
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There are 10 principles of DFMA to consider
Source: http://www.unm.edu/~bgreen/ME101/dfm.pdf Huiying Tan 30
1. Reduce the total number of parts
4. Design parts to be multi-functional
2. Develop a modular design
5. Design parts for multi-use
3. Use of standard components
6. Design for ease of fabrication
7. Avoid separate fasteners
8. Minimize assembly directions
9. Maximize compliance
10. Minimize handling
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Sustainability Applying Sustainability to Telepresence Robots 1. I will use innovation by providing the product as a service. 2. I will be using renewable resources. 3. I will look for to minimize number of materials and components. 4. I will reduce product and packaging weight 5. I will design for renewable energy 6. My design will be durability 7. I will apply resueful compoennents to my design 8. I will apply recycleable materials that provide the ability to biodegrade.
“Eight steps to reducd the ecological impact of products�
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Who you know
As you grow in the industry, you will develop relationships with manufactures. Ask people who you already know is a good way to provide you good work. You may also save some money in long run
Manufacturer Selection Selecting a manufacturer is a significant process of your design. Here are some considerations when you are selecting a manufacture.
Trade Shows
Trade shows can be a good place to know some new manufacturing process or technology. You can have firsthand experience to feel and to see the parts, materials., et.
Manufacturers Rep
Manufacturer Rep allows more people to know their business. You can rely on their connections and experience. They would like to answer all the questions and help your business.
Internet Research
The Internet is a great source to look up manufactures. Thomas Guide is another research tool that can assist the manufacturer selection process.
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Manufacturer Selections
LOW VOLUME SAND CASTING
METEOR FOUNDRY CO.
GENERAL FOUNDRY
DANDONG FUDING ENGINEERING MACHINERY CO., LTD
New York COST: HIGHT QUALITY: HIGHT CAPACITY: HIGH
San Leandro, CA Cost: Medium Quality: Very High Capacity: Medium
CHINA COST: LOW QUALITY: LOW CAPACTIY: VERY HIGH
“Serving the industry for almost half a century Meteor Foundry Co. delivers quality sand and gravity permanent mold castings in a wide range of certified Aluminum and Zinc alloy castings in sizes from ounces to 4000 lbs.The company’s success can be attributed to emphasis on process and technology supported by a team of experienced knowledgeable staff and professional management.”
“We Pour Molten Metal into Useful Shapes in a Precise, Economical, & Timely Manner using Precision Sand Casting, No Bake (Air Set) Sand Casting, Rubber Plaster Molding (RPM), & Permanent Mold Processes.” We show expertise in CNC Machining, Finishing, and Assembly. It is General Foundry Service’s quality, engineering, and on time deliveries that keep our customers coming back.
“Dandong Foundry, is a professional Iron Foundry in China. Producing Grey Iron and Ductile Iron Castings over 2000 types. The annual production of our foundry can reach 10,000 tons and 60% have been exported to USA, Germany, Australia, UK and Japan. Our new foundry plant has more larger automatic molding lines and more machining equipments. The max. production capacity of gray iron and ductile iron castings could reach 30,000 tons each year.”
I choose DANDONG FUDING for my sand casting manufacturing because my design contains many parts and they can produce a large ammount of units.
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Manufacturer Selections
LOW VOLUME PRESURE FORMING
MAAC MACHINERY
EDWARDS
FREETECH PLASTICS
CAROL STREAM,ILLINOIS COST:MED QUALITY:HIGH CAPACITY: HIGH
CHINA COST:LOW QUALITY:MED CAPACITY: HIGH
FREMONT,CA COST:HIGH QUALITY:HIGH CAPACITY: LOW
MAAC designs and builds custom thermoforming machinery in both Shuttle and Rotary configurations. Each model has over 300 application specific, subassembly component options that may be integrated into the final product. MAAC will utilize your application specific requirements to compile and furnish exact machine specifications.
“As a trusted partner, we have wellestablished customer relationships with many of the world’s leading manufacturers and a deep understanding of their key process challenges. Interaction. Commitment. Innovation. There are the values that are reflected in how we behave internally and in our relationships with external stakeholders.”
“Freetech Plastics is committed to achieving one goal: “To make it like you want it.” For over 40 years we’ve provided precision Pressure Forming parts for the Automotive, Medical, Scientific, Telecommunication, and Electronic Enclosure markets.
I choose MAAC MACHINERY for my presure forming manufacturing because they are in US and they can produce large, and high quality quanities.
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Manufacturer Selections
High VOLUME INJECTION MOLDING
DINESOL PLASTICS INC.
KNIGHTSBRIDGE PLASTIC INC.
ECO MOLDING CO.,LTC
NILES, OH COST:MED QUALITY:HIGH CAPACITY: HIGH
Fremont, CA COST: HIGH QUALITY: VERY HIGH CAPACITY:LOW
CHINA COST: LOW QUALITY:LOW CAPACITY: VERY HIGH
“Dinesol gets it done! With a modern plant and equipment, consistent and aggressive people with years of experience, quality, financial stabililty, and capabilities to take ideas to finished products, they are your plastics solutions partner.”
“Kightbridge Plastics. Inc. Has been an industry leader since 1982 in the field of innovative mold making and the production of intricate close tolerance tooling and plastic injection molded parts and components for a wide spectrum of industries and applications.”
“Eco moldingCo.,Limited , Eco molding offer plastic injection molding service and specializes in various plastic moulds for. automotive, home appliances, electronics ,as well as general industrial OEM applications. Our company covers an area of more than 2000 square meters workshop, surrounded with convenient transportation.”
I choose Dinesol for my injection molding manufacturing because they are in US and they can produce a large ammount of units. Their part quality is high as well.
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Manufacturer Selections
High VOLUME PROG.DIE STAMPING
HPL STAMPINGS,INC.
JL PRECISION
ZEEN
SPRINGFIELD,ILLNOIS COST:MED QUALITY:HIGH CAPACITY: HIGH
SAN JOSE, CA COST: MED QUALITY: VERY HIGH CAPACITY:HIGH
CHINA COST: HIGH QUALITY:VERY HIGH CAPACITY: LOW
“Our innovative tooling methods & recent laser cutting advances allow us to blend our custom metal stamping expertise with sheet metal fabrication technology, resulting in a complete “unlimited” metalforming service previously unheard of in our industry. We do it all.”
“The goal of JL’s Quality Program is to achieve 100% customer satisfaction by producing precision sheet metal and machining solutions with the best quality, on-time delivery, and service. JL strives to provide products that consistently meet customer and regulatory requirements, and to enhance customer satisfaction through the effective application of continuous improvement principles”
“the company possesses a team of 200 associates widely recognized for its excellent capacity throughout a large number of countries.Our high quality products include progressive, line and transfer dies ranging from 160 to 1000 tons presses.”
I choose JL Precision for my progressive die stamping manufacturing because they are in local and they can produce large, and high quality quanities.
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Branding Low Volume
Methods- Looking for an special and elegant solution Printed Hand Painted Airbrushed UV Printing Hydro Priniting Applied: Wood Burning Cast metal Nameplate Integrated: Cast Embossed/Debossed Laser Cut Texture Machined
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Machined Machining my brand onto the cast metal in this case means griding down the rough gritty exterior until it’s flat. This will make my logo pop out.
Branding High Volume
Methods- Looking for an innexpensive solution Printed: Spray painted Silkscreen Pad Printing Applied: Stamping Labels Sticker Integrated: Texture Change Two Shot molding Injection molding Stamped/ Die Punched
Molded Injection molded is innexpensive branding feature. I chose this method because it will be cheap, look great on my robot.
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High Volume COSTED BOM
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Low Volume COSTED BOM
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Regulatory Agencies
Maintaining Safety standards in Manufacturing
CE MARKING
A mandatory conformity marking for certain roducts sold within the European Economic Area. The CE marking is the manufacturer’s declaration that the product meets the requirements of the applicable EC directives
Underwriters Laboratories
UL provides safety-related certification, validation, testing, inspection, auditing, advising and training services to a wide range of clients, including manufacturers, retailers, policymakers, regulators, service companies, and consumers.
Canadian Standards Association
A not-for-profit standards organization which develops standards in 57 areas. Provider of product testing and certification services for electrical, mechanical,plumbing,gas and a variety of other products.
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Regulatory Agencies
Maintaining Safety standards in Manufacturing
US Food and Drug Administration
The FDA is responsible for protecting and promoting public health through the control and supervision of food safety, tobacco products, dietary supplements, prescription and over-the-counter pharmaceutical drugs (medications), vaccines, biopharmaceuticals, blood transfusions, medical devices, electromagnetic radiation emitting devices (ERED), cosmetics, animal foods & feed and veterinary products.
Occupational Safety and Health Administration
is an agency of the United States Department of Labor. OSHA’s mission is to “assure safe and healthful working conditions for working men and women by setting and enforcing standards and by providing training, outreach, education and assistance”
International Organization for Standardization
the organization promotes worldwide proprietary, industrial and commercial standards. It is the world’s largest developer of voluntary international standards and facilitates world trade by providing common standards between nations. Nearly twenty thousand standards have been set covering everything from manufactured products and technology to food safety, agriculture and healthcare. 43 Huiying Tan
Material Selection Reasons to pick a material • Price • Finish Price • Texture • Finish Texture •Manufacturing abilities •Contrast in Material •Functionality •Assembly Quality • Durability of material Speed of manufacturing Effectiveness Upgradability Variety Secondary Ops Location Aesthetics • Current Trends Sustainability • Recycle - ability • Ecologically sourced • End of life • Lifespan • Amount of energy to process Safety • Products of material Huiying Tan 44
Material Selection Low Volume
Titanium
Durable/Lightweight High Specific Strength Corrosion Resistance High Purity
Aluminium 6061
Good Weldability/ brazability High strength Lightweight Less expensive
Stainless steel
Weldable Machinable Good corrosion Lightweight
Decision For the main body of my low-volume robot, I chose Titanium, Aluminium 6061 and Sterling Silver. I selected these materials because they are lightweight, durable, and can be easily formed and punched. I will select titanium as my final choice because it would be strong and lightweight. Cold and metallic to the touch while adding weight to the product. 45 Huiying Tan
Material Selection High Volume
PVC
Flexible Low Cost Strong
Plexiglass
Low Cost Lightweight Strong
ABS Plastic
Strong Good processability and apperance Good impact resistance
Decision For the main body of my high-volume robot, I chose rigid PVC, Plexiglass and ABS Plastic. I selected these materials because they are good impact resistance and can be easily formed. I will select Plexiglass as my final choice because it would be good processability and apperance.
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CMF Mood Boards Color-Low Volume
Fresh Aqua Sky PANTONE14-4811
Sophisticated Hexachrome Black PANTONE 2D2926
Powerful Chili Pepper PANTONE 19-1557
Color Selection I choose these three colors because they are popular in speaker products. Color express emotions. I think my color selections reflect to my persona ‘s personality.
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CMF Mood Boards Materials -Low Volume
Anodized Aluminum
Material Selection
Cast Steel
These materials will be my potential selections on the main body part. Anodized Aluminum is bright and shiny on the surface. Cast Steel will be on the speaker part because I like the material looks very rugged. Wood will provide better sounds
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Walnut Wood
CMF Mood Boards Finish -Low Volume
Anodized aluminum
Powder Coatings
Walnut Wood finishes
Finish Selection
I choose anodized aluminum for my finishing process because it accept vibrant colors. Powder coatings do not contain volatile organic compounds(VOC). This is good for meeting environmental regulations on VOC.
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CMF Mood Boards Color-High Volume
Joyful
Positive
Harmonious
BUTTERCUP PANTONE 12-0752
GREEN FLASH PANTONE 15-0146
SNORKEL BLUE PANTONE 19-4049
Color Selection I choose these three colors because these colors are 2016-2017 popular pantone colors. Since my robot is designed for music therapist,I want to provide a joyful and delightful look to my persona.
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CMF Mood Boards Materials -High Volume
Polypropylene
Plexiglass
ABS Plastic
Material Selection I like ABS plastic on the main body part because it smooth and shiny. Polypropylene will be on the speaker part because I like the material looks very flow.
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CMF Mood Boards Finish -High Volume
Texture
Finish Selection The texture is will be on my speaker part. I want to provide a glossy and bright looks. Faux-metal plastic looks shiny on my robot. I think these finishes method will match to my persona
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Gloss
faux-metal plastic
CMF Color Material Finish
Color There are several tools to work in when dealing with color. For example, RALPaint, PMS(Pantone), MFR (cardinal)., etc.
Materials Material selection is crucial because it important to consider aesthetics and target market. When selecting materials, it is also important to ensure performance and functionality.
Finish The finish of a surface has a important impact on the final look, such as texture, cleanability, durability, gloss, mate, and qualities.
COLOR MATERIAL FINISH HIGH VOLUME MODEL
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DIRECTION ONE CMF
SEMI-GLOSS WHI
BRUSHED NICKEL PLA ED ZAMAK
SEMI-GLOSS WHI EVI ON
DIRECTION TWO CMF
SILVER
PAIN ED FLA BLACK ZAMAK
SILVER ME ALLIC VI ON
DIRECTION THREE CMF
GLOSS RED
ANODIZED ZAMAK
Selected
It looks clean and inviting in the home and workspace setting. It is neutral,and elgant
FLA RED VI ON
HIGH VOLUME BILL OF MATERIAL NUMBER AMOUNT NAME 1 1 Front Shell
PROCESS Laser Cut
2
1
Back Shell
3
2
Speaker
4
3
Speaker Frame
5
1
Screen Frame Die Casting
6
1
OLED Screen
7
1
Button set
8
1
Wheels
9
3
Charging Port
10
1
Audio Chip
11
2
Computer Chip
12
12
Fasteners
13
1
Battery Box
7.
Injection Mold
4.
Injection Mold Injection Moold
3.
1.
2.
12.
Injection mold
6.
11.
5. 10.
13.
8. 9.
Snap fit
COLOR MATERIAL FINISH LOW VOLUME MODEL
DIRECTION ONE CMF
Walnut
ANIUM MIL-A-8626 anodize
Brass Slenium Dioxide
DIRECTION TWO CMF
MAHOGANY
POLISHED II ANIUM
Selected
The look appeals to market
PRO EC ED POLISHED BRASS
DIRECTION THREE CMF
BLACK MAHOGANY
ANIUM MIL-A-8625 ANODIZE
BLACK GLOSS FINISH
LOW VOLUME BILL OF MATERIAL 1
NO. DESCRIPTION QTY MATERIAL PROCESS 1.
Upper Speaker 2
3.
Sand Casting
2
box 2.
Lower Speaker 2
7.
Sand Casting
box
4.
3.
Speaker
2
RIM
4.
Upper box
1
Sand Casting
5.
Lower box
1
Sand Casting
6.
OLED Screen 1
Laser Cut
7.
Stand
3
CNC Machined
8.
Button Set
1
9.
Upper Body 1
Box 10. Lower Body
6. 5. 8.
Sheet forming Sheet Forming
1
Box 11. Power Supply 1
9. 11. 10.
High Volume Design
High Volume Design
High Volume Design
Low Volume Design
Low Volume Design
Low Volume Design
Telepresence Robot
High Volume Design
Low Volume Design
Manufacturing Processes: Injection Molding, Die Casting Materials: Plexiglass, Zamak, Aluminum Cost: $1889.67 Volumes: up to 100,000units
Manufacturing Processes: Sand Casting,CNC Machined Materials: Mahogany, Titanium, Brass Cost: $26469.05 Volumes: up to 1,000units
Thank you