Integrated Studies Light Project Folio Stephen Boyle
Zhengnan Su
Marc Craig
Contents Page Brief.................................................................Page 1 Assesment Criteria........................................Page 2 Gantt Chart...................................................Page 3 Market Board (Lights)....................................Page 4 Market Board (Toys)......................................Page 5 PDS I................................................................Page 6 Visual Brainstorming......................................Page 9 Form Ideation..............................................Page 10 Initial Ideas...................................................Page 11 Development..............................................Page 12 Final Model..................................................Page 24 CAD Renders...............................................Page 25 CAD Drawings.............................................Page 26 Bill of Materials.............................................Page 30 Tools Used.....................................................Page 31 Calculations.................................................Page 32 Branding.......................................................Page 33 Poster............................................................Page 34
Page 1
Assessment Criteria Model & Presentation - 30%
Folio Submission 20%
Model (50%)
As part of the folip you need to submit for the 2nd part of the assignment, the following information will have to be included in your team folio submission:
Aesthetic Appearance (10%) Level of Difficulty (10%) Creativity (10%) Functionality (10%) Quality of Manufacture & Assembly (5%) PDI - Effectiveness of Branding (5%) Presentation - (50%) Range of Concepts Considered Evaluation Process Manufacturing Methods / Problems Encountered/Solved Unique Features of Your Design (Why Will it Be Successful?) PDI - Emphasis on Branding Last Slide Should Be a Poster Advertising Your Product
Outline Sketches for Ideas, Plus CAD Drawings for Each Component (40%) Rendered Images of Assembly (15%) Calculations (10%) Bill of Materials (5%) Justification of Why You Used Individual CAM Technologies and Their Limitations (10%) Poster Presentation Board (5%) A Section on the Course Specific Content (e.g. Calculations of Battery Life) (10%) Submission Model - 5pm Week 9 Folio - Week 10
Page 2
Gantt Chart Week 1
Week 2
Week 3
Week 4
Week 5
Week 6
Week 7
Week 8
Week 9
Week 10
Theme Board
PDS Sketch Concepts EVALATION & CONCEPTS
PMI CCM Weighting Matrix Develop Ideas User Feedback Solidworks Final Model
PRESENT & FINAL
Presentation Boards
PRESENTATION
Light Research
MODEL HANDIN
Market Board
MILESTONE
RESEARCH & PREP
Gantt
Poster Finish Folio PowerPoint Present
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Market Board (Lights)
Researching existing light products designed for children not only shows us whats already out there but also how the product has been showcase/photographed, which will help us when it comes to the poster etc. We can also look at potential context scenes with these images which will help us with producing the poster later on
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Market Board (Toys)
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Product Design Spec. I 1.0 Performance
6.0 Life in service
1.1 The LED light’s source of energy must be renewable. 1.2 The LED light’s level of luminance must not jeopardies the child’s eye-safety. 1.3 The product must provide a stable source of lighting. 1.4 The product must be convenient to store.
6.1 The product should have an average life expectancy of 3-5 years 6.2 The product should suit for children between 3-9 years old. 6.3 After use the product must be capable of being fully recycled.
7.0 Timescale 2.0 Material 2.1 The product should be constructed of non-toxic materials. 2.2 The product should be made of materials that are not highly flammable or easily broken. 2.3 At no point should the paints used on the product be dangerous and always lead-free. 2.4 Materials used must consider needs of the child. 2.4.1 There should be no sharp edges or protruding corners. 2.4.2 Should consider softer materials.
7.1 This project shall last 10 weeks and the production process shall take 4 weeks after specific date. 7.2 The timescale was originally set out in the brief, and them mapped in a Gantt Chart. SEE PAGE 4
8.0 Ergonomics 8.1 The product should be easily set up by one person. 8.2 No sharp edges will be exposed to comply with the British safety standards. 8.3 The product should supply an adequate hand grip to ensure easy operation for children.
3.0 Quality 9.0 Aesthetics 3.1 The product should be of such quality that no small parts could be dislodged and by chance swallowed by the child. 3.2 The LEDs used in the product must be of the highest viable quality so to prolong longevity of life. 3.3 the product should withstand drops from height given the clumsy nature of children.
4.0 Documentation 4.1 all relative documentation such as; instruction manuals, warranties, and guarantees should be included with the product. 4.2 The company must keep accurate and up to date records of all important licensing and patent documentation. 4.3 Appropriate documentation should be kept confidential.
5.0 Legal 5.1 For the product to sell in the UK it must comply the standards as follows: 5.1.1 ISO 8124, Part 1, Safety aspects related to mechanical and physical properties; 5.1.2 ISO 8124-2, part 2 Flammability; 5.1.3 IEC 62115, Electric Toys -Safety; 5.1.4 IEC 60825, Laser/LED Safety.
9.1 Our company logo should be clearly visible on product. 9.2 The product should be appealing to the child 9.1.1 The use of bright colours shall be incorporated. 9.1.2 All Corners and edges shall be rounded and soft. 9.1.3 Child centric detailing shall be considered 9.2 The shape of product must be aesthetically pleasing to attract potential customers.
10.0 Safety 10.1 Choking Risks – Due to the high probability of child interaction, if the subassembly has any parts which are deemed as a choking hazard for children (by testing using a small part cylinder) then it must bear a ‘Choking Hazard Warning’. 10.2 Magnetic Parts –The subassembly cannot contain magnets with a flux more than 50kG2mm2 (0,5 T2mm2) which can fit into a small parts cylinder 10.3 Chemicals – The European Directive 2009/48/EC which limits the number of chemicals that can be present in the materials used for products that have child interaction, must be strictly followed 10.4 Form & Function– The form of the subassembly must not cause any harm to the user 10.4.1 sharp edges or how the subassembly works must not strain the user physically 10.5 The subassembly must meet the testing standards by the EN 1888 norm,
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Product Design Spec. I 11.0 Customer
17.0
11.1 Average age of new families in UK – 28 years old 11.2 Average age of new families (Global) 25.2 years old 11.3 The user should be able to provide feedback, this will assist in further research and development of the both the product and the company as the move forward. 11.4 The user should feel safe and comfortable whilst using the product. 11.5 The product should be engaging enough for the parent and child to engage with it regularly.
17.1 The toy must have a renewable energy powered LED light installed as this is the main purpose of this project. 17.2 The fixings for the mechanical features should allow easy access for maintenance issues. 17.3 The fixings used must be durable and flexible to ensure durable mobility and performance. 17.4 The toy must have a safe installation process. 17.5 The toy must have instructions on how to install and work the device.
12.0 Size
18.0 Market Constraints
12.1 The size of the product must be corresponding to the correct Child Anthropometric Data to determine the correct dimensions for safety and physiology purposes. 12.1.1 The solution should consider innovative approaches to arrangement of masses and dimensions. 12.1.2 The size of the toy should be able to fit inside a child’s hand. Further research must be carried.
18.1 Initially starting locale in Glasgow and then the rest of the UK. 18.2 If the product is successful in our UK ventures, we would like to branch out into the European Market and then the Global Market.
13.0 Processes 13.1 Full use of all available facilities and resources within the university shall be used to produce the best product. 14.0 Manufacturing Facilities 14.1 To manufacture our product we shall fully utelise all the equipment provided within the workshop environment of the university.
15.0 Weight 15.1 The overall weight of the subassembly should be kept to a minimum due to the high child interaction . Specific weights will be specified later in the process.
16.0
Company Constraints
16.1 The company face time constraints. These constraints and present by the deadlines set by the brief and client. See 7.0 Timescale 16.2 The company face financial constraints at present. In pursuit of the new processes and materials the company must pay due concern to overall costings. Negotiations may be needed to pursue specific avenues (materials, processes, shipping etc.) 16.3 The company face resource constraints at present. Due to the small team in operation. The team must pay due concern to allocation of manpower and careful consideration to task delegation to the work force.
Installation
19.0 Political & Social 19.1 All parts of final solution should be obtained from British companies were possible. 19.2 Consideration should be made when naming the product when exported to non-English speaking countries. 19.3 The product should not be exported to any country where a current trade embargo exists. 19.4 Marketing scheme should be taking into consideration due to dealing with children as many find this a sensitive subject, so when branding and advertising, pitching a sensitive approach should be advised.
20.0 Competition 20.1 Home Stores - IKEA is a very large global company that provides many household items including a wide range of children’s lighting. This company is already a widely recognised household name so wil be a direct completion. 20.2 Toy Stores – Smyths, Argos, Toys’R’us. Well known toy manufacturers are another form of direct competition, being widely known for their entertainment goods. 20.3 Garden Goods Retailers – it is not uncommon for such group to sell good aimed for kids in the gardens to act as toys. 20.4 Early Development Stores/Nursery Super Stores – Mother care and like store offer everything for children’s clothing to children’s toys so can also be considered as a direct competitor.
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Product Design Spec. I 21.0 Product Cost
26.0 Standards/Specification
21.1 As a profit orientated enterprise, all materials used shall be selected with this in mind. This means that the end product shall be completed at the lowest possible cost without compromising in product quality (3.0), safety (10.0), or economic impact ^^^. 21.2 To maximize profits, outsourcing of parts and production methods shall be employed allowing us to focus on design aspects to make the product the best it can possibly be.
26.1 British ISO standards set by British Gorvernment 26.2 PD CEN/TR 13387 (2004): Specification for child use articles. Safety guidelines
22.0 Packaging 22.1 Packaging should be kept to a minimum to reduce waste. 22.2 Should incorporate appropriate artwork to adequately display and advertise the product without the packaging having to be disturbed by prospecting customers. 22.3 should protect the product during transit from knocks and bumps as well as general shipping conditions.
23.0 Patents 23.1 No patents should be breached with regard to any aspect of this product. *Patents to be specified at later stage*
24.0 Product Lifespan 24.1 The product should be able to withstand 5 years of wear and tear under child’s ownership. 24.2 Within a reasonable time period, the child should not rust or corrode under reasonable circumstance. 24.3 The Product should no break or be damaged under reasonable circumstance; i.e whilst being used daily by a child for a prolonged period of time with all that entails. *If the product does not perform in this area as it should, by breaking as a result of manufacturing or design errors, a suitable replacement should be available with a warranty and proof of purchase. *
27.0 Environment 27.1 The product will cause as little environmental impact as possible by ensuring that its carbon footprint is as low as possible from every aspect from the design phase, manufacture phase, shipping, and finally its life span. 27.2 The product must have full environmental efficiency in terms of disposal meaning it can be fully recycled after use.
28.0 Shipping 28.1 Shipping of the component must be swift and safe. As we plan to outsource, we must adequately plan arrival of all parts in an appropriate time frame. 28.2 The product should be designed in such a way that shipping of the products can be done efficiently and quickly to ensure customer loyalty with our brand. 28.3 It should be able to be shipped in large quantities to ensure low costs of shipping and to reduce emissions. 28.4 The product should be adequately packaged to avoid damage whilst shipping.
29.0 End User 29.1 The end user of this product shall be children aged 3-9 years. 29.2 Aesthetic and functional aspects shall be focused toward this age range so the user can easily learn how to use it.
25.0 Maintenance 25.1 Maintenance to this product should be minimal with exception to changing of the lighting element, or batteries.
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Visual Brainstorming
Using Post-It Notes, we explored the different ways we could power the light and came quickly came up with ideas and placing them in the corrosponding catergory in how they will be powered. Visual brainstorming was productive as we were able to rumage through wacky ideas to find ones that jumped out (blue circled).
Page 9
Form Ideation
Starting off with quick form ideations helps loosen up when it comes to coming up with more refined ideas. The reason for doing this is to try to encapture what makes a product look ‘child-friendly’ and apply it in forms to create a more semiotically fitting design later on
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Initial Ideas
Chosen Concept
Page 11
Initial Ideas
After using the post it notes we went on to more thought out ideas that where feasible. We still wanted to keep an open mind into what types of enerrgy source we can use to free up the constraints of our idea generation stage. After much discusion we agreed on the toy police car idea. We picked this as we thought we it was an idea which is possible, we could have fun when doing the branding aspect like the posters and adverts, and overall it would be a cool idea if we can get it working.
Page 12
Development
To start we tinkered about with gearboxes and set them to a ratio of 125:1. We calculated that 4 gearboxes will be enough to power the 7V L.E.D.
We started to come up with rough dimensions by laying the components we need on paper and drawing rough orthos to give us estimates.
Using 4 gearboxes to light the LED which are powered by the rotation of the wheels attached to the axle. Well thats the plan
To connect the gearboxes and wheels in the picture to the left together we had to make a chassis. So we laser cut one minimising material and weight
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Development
We glued the gearboxes to the chassis which will keep them steady. Now we can work out the axles which will run through the gearboxes also.
Zhengnan showcasing our laser cut acrylic chassis
We can now begin to start on creating the car body now we have these dimensions
Page 14
Development
Using the scroll saw to cut out profiles out of MDF. This machine can give nice rough shapes but is difficult to get precision in shaping
After cutting a few defects we chose a bundle of profiles that were usable for the vacuum forming later on
We glued the profiles together using wood adhesive and a couple of clamps. We noticed the profiles aren’t identical which we’ll fix later on
Adding fendors to the shape gives more realism. Also we need them because the main body wasn’t wide enough to fit the chassis
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Development
The band saw allowed us to square the mold. This was a lot quicker than trying to use the scroll saw or even try to sand it down.
Additional sanding had to be done to give rounded edges to give that child friendly signifier.
Polyfilla helped us fill in the bumps and dents in the mold to make it flush. We caked it on as we knew from previous projects it sands like a dream.
Whilst waiting on the mold glueing together, we sketched on dimensions which will help us when it comes to making the Solidorks files.
Page 16
Development
We had to buy M3 threaded rod as using a tap and die to thread a blank would take too long. This will help the geears grip plus attach the wheels using nuts.
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Development
Using the scroll saw to cut out profiles out of MDF. This machine can give nice rough shapes but is difficult to get precision in shaping
After cutting a few defects we chose a bundle of profiles that were usable for the vacuum forming later on
Adding fendors to the shape gives more realism. Also we need them because the main body wasn’t wide enough to fit the chassis
Adding fendors to the shape gives more realism. Also we need them because the main body wasn’t wide enough to fit the chassis
Page 19
Development
Soldering the Circuits
Page 20
Development
Page 21
Development Once the car shell was formed, sandpaper was applied to rough up the surface to allow the primer and paint to stick
Page 22
Development
From the measurments of the model we were able to make decals on Illustrator . We toyed with the idea of making it a ‘Polis’ car so we printed off decals incase we decide to use them
Page 23
Development
After the decals were applied we were ready to attach the bottom to the shell. We had to extended the wires as the LEDs did not reach the siren once the shell was on top. We hot glued some foam to the gear boxes with cardboard as a buffer. The top was hot glued in place
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Final Model
Page 24
CAD Renders
Page 25
80
260
CAD Drawings
210
261
11
Quantity: 1
Material: N/A
Manu: N/A
Date: 23/03/2017 Signature:
Colour: N/A
Part Number: N/A Scale: 1:2
Designers: Team 26 Name of Part: Car Assembly
CAD Drawings
135
2
125.75 260
90
3
R5
25
R8
R9 7
0 R8
5 R6
0
R5
41 20
TRUE R5
0 R3
52
0
R3 30
59 Quantity: 1
Material: PS
Manu: Vacuum Formed
Date: 23/03/2017 Signature:
Colour: N/A
Part Number: 1
Scale: 1:2
Designers: Team 26 Name of Part: Car Shell
Page 27
CAD Drawings 5
.54
4
150 140
DETAIL C SCALE 2 : 1
0
R3
A
115
105
85
75
30
10
3.
01
±0
.0
2
26
20
R1
4
C
Quantity: 1
Material: Acrylic Colour: Blue
Manu: Laser Cut
Date: 23/03/2017 Signature:
Part Number: 2
Scale: 1:2
Designers: Team 26 Name of Part: Chassis
32
SECTION A-A
34
3
95 85 65 55 10
2.1
R8
R1
A
Quantity: 4
Material: N/A
Manu: N/A
Date: 23/03/2017 Signature:
Colour: N/A
Part Number: 3
Scale: 1:1
Designers: Team 26 Name of Part: Tyre
Bill of Materials
4
5
8
1
4 Bill of Materials ITEM NO.
3 PART NAME
1
Car Shell
2
Chassis
DESCRIPTION Aesthetic component that houses the insides Holds the gearboxes
QTY.
3
Tyre
Provides traction
4
4
Gearbox Ratio 1:125
Outsourced. Charges battery
4
5
120 X 3 Threaded Rod Allows wheels to turn .
2
6
M3 Nut
Outsourced
8
7
M3 Wahser
Outsourced
8
8
LED
Emitts light
1
9
Siren
Holds LED
1
1 1
2
6
7
Page 29
Tools Used
Vacuum Former
Laser Cutter
We used the vacuum former to produce the shell of the car to hold the insides. We decided to use this as we could achieve the rounded form we wanted. It took ages to make the mold however as sanding the MDF took forever.
To get the chassis shape we wanted we made a drawing on SolidWorks and used the laser cutter. Since it was only a flat surface we needed the laser cutter was appropriate.
Pros
Cons
Nice surface finish Difficult forms Cheap
Needs MDF mold Takes 45mins to heat Limited materials
A couple of efforts that didnt work out
Pros
Cons
Quick Simple to use Different Colours
Suited for small scale Waste of material Queues
What we made with the laser cutter
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Calculations Component
Ba�ery
LED
Wheel
Motor
Required Informa�on
Value
Voltage Capacity
1.5V 3500mAh
Voltage typical Voltage max Voltage average Power Current
2.9V 3.1V 3.0V 108mW 30mA
Diameter Mass
62mm 33g
Voltage Current (max) Power Rotaďż˝onal Speed Torque EďŹƒciency
1.5V/3V 0.26A/0.41A 510mW 4300rpm 15.5g-cm 38.8%/46%
By using this number and the gear ra�os we can calculate the torque experienced by each gear and by extension the force needed to act upon each wheel to give each motor (generator) an output of 0.7V.
From this it can be see that if each wheel spins at 1.1005ms-1 then 0.7V will be produced by each motor.
Motor Gear to Gear 1 (white 50-10)
At 0.7V each motor (generator) will be generaďż˝ng ≈ 0.56A, totalling the number of motors (generators) we can calculate the total current produced by all motors (generators) at this speed;
Ď„0 Ď„đ?‘– đ?‘›
đ??ź
50 Ď„0 = 0.0015 10
Ď„0 = 0.0075đ?‘ đ?‘š
đ??ź
Gear 1 (white 50-10) to Gear 2 (red 50-10)
Ď„0 Ď„đ?‘– đ?‘›
đ?‘Ą
Ď„0 = 0.0375đ?‘ đ?‘š
If the torque required on the ďŹ nal, most outer, gear is 0.0375Nm the torque required to act on each wheel would be the same. From this informaďż˝on, we can then calculate the force that each wheel would have to have applied to it; Ď„ = Fr
therefore;
F=
It can be see that when a voltage of 3V is applied to the motor (generator) it produced a rota�onal speed of 4300rpm. From this we can deduce that if our 07.V where to be applied then a rota�onal speed (ω) would be 1003.33rpm would be generated.
F=
ω=
1003.33 60
0.0373 31đ?‘Ľ −3
ω = 16.72radđ?‘
đ?‘?đ?‘š 15đ?‘”
9.80665đ?‘Ľ đ?‘?đ?‘š
đ?œ”
√(
2
1
−5
đ?‘ đ?‘š
0.0015đ?‘ đ?‘š
đ?œ”
√( 33đ?‘Ľ đ?œ”
đ?‘Ł
đ?‘Ł
đ??š
)
1.25 đ?‘Ľ 31đ?‘Ľ
−3
35.5đ?‘&#x; đ?‘Ž đ?‘‘ đ?‘ 1
đ?‘Ł
đ?‘? đ?‘Ž đ?‘? đ?‘Ž đ?‘? đ?‘– đ?‘Ąđ?‘? đ?‘Śđ?‘˘ đ?‘&#x; đ?‘&#x; đ?‘’ đ?‘› đ?‘Ą đ?‘Ą
đ?‘Ą
3500 2240
1.5625â„Žđ?‘œ đ?‘˘ đ?‘&#x; đ?‘
From there being no charge in the ba�ery to it being at full capacity it would take nearly 1.6 hours of con�nuous use at a speed of 1.1005ms-1
đ?œ”đ?‘&#x;
35.5 đ?‘Ľ 31đ?‘Ľ
đ??ź = 30 + 30 + 30 + 30 + 30 + 30 + 30 đ??ź = 210đ?‘š đ??´
By calcula�ng this current, it can now be seen how long the seven LEDs can run on a ba�ery of full charge;
đ?œ” =đ??š đ?‘š đ?‘&#x;
From the data table insert ďŹ gure no. shown above, it can be seen the motor (generator) produces 15.5g-cm of torque (Ď„). If; 1đ?‘”
đ?‘š đ?‘&#x;
2240đ?‘š đ??´
đ??ź = đ??ź +đ??ź +đ??ź +đ??ź +đ??ź +đ??ź +đ??ź
F = 1.25N
đ??š
2.24đ??´
If each LED has a current requirement of 30mA, then it can be see seven LEDs in parallel would have a current ra�ng of;
Ď„ r
From this we can go on to calculate the speed that the vehicle must travel at to illuminate the LEDs.
Conver�ng this number to rads-1;
đ??ź
0.56 ∗ 4
If the capacity of the ba�ery is 3500mAh, we can calculate how long it would take this circuit to fully charger the ba�ery;
n0 nđ?‘– đ?‘›
Ď„0 50 = 0.0075 10
During an experimental phase, a wheel was a�ached to an axel joined to the gearbox which housed the motor (generator). A voltmeter was then used to measure any voltage generated by the motor (generator). When the wheel was hand cranked - rotated by hand - it produced a voltage of 0.7V across the motors (generators) terminals.
Then;
n0 nđ?‘– đ?‘›
−3
1.1005đ?‘š đ?‘ 1
−3
)
đ?‘? đ?‘Ž đ?‘? đ?‘Ž đ?‘? đ?‘–đ?‘Ąđ?‘Ś đ?‘œ đ?‘“đ??ż đ??¸ đ??ˇ đ?‘
đ?‘Ą
đ?‘Ą
đ?‘Ą
3500 210
16.6â„Žđ?‘œ đ?‘˘ đ?‘&#x; đ?‘
Page 31
Branding
Due to the funny shape to our car we found it difficult to capture the car in a real life situation therefore we looked into classic car posters for inspiration. The bright colours and the striking shapes will both engage the kids and the adults
Page 32
Poster
Page 33
Reflection Positives ∙ Passed the class. ∙ Experienced working with poor English speaker. ∙ Complimented on sketches. ∙ Gained model making confidence. ∙ Teammates liked the folio put together. ∙ Learned about what the Uni looks for. ∙ Deadlines met. ∙ Maintained a folio aesthetic. ∙ Discovered great printing place.
Things to Work On. ∙ Poor presentation (not prepared) ∙ Spend more time learning in the workshop ∙ Plan doing multiple projects ∙ Get better pictures to document ∙ Don’t worry about liking team members ∙ Remember projects are projects.
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