Product Design Portfolio 2017 PO-HAN HUANG
SOFTWARE SKILL
INTRODUCTION
Design thinking 5
2D Adobe indesign Adobe photoshop Adobe illustrator 3D Autodesk Solidwork Rhino Keyshot Program C/C++/C# HTML CSS .NET
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I am Po-Han Huang, a postgraduated integrated product design student in Brunel university.
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Execution
2 1
Design communication
I used to be a mechanical engineer and I specialized in automatic control, such as CNC machine and robot control. I hope to understand more about user’s behaviour and design thinking skill. Therefore, I came to UK to start my design journey.
Team working
System thinking
To be a designer for me is about engaging people and make things happen.
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CONTACT ME stigersmile@gmail.com
Index UX design
P4 | Style
Branding design
P18 | Mano hand
Human factor design
P28 | GOOD FIT
Sustainable design
P40 | Redesign heater
Company project P52 | RB P53 | RBADY
Mechanical design
P54 | Three-Axis robot arm P56 | Manufacture CNC milling
Others
P58 | Wood handcraft P60 | UI design P61 | Sketch
SYMBOL INDIVIDUAL PEOJECT TEAM DISCOVER DEFINE DEVELOP DELIVER
PROJECT
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INTRODUCTION
Nowadays, smartwatchs have become popular. However, the young generation prefers to use smartphone rather than wear a watch The project aims to design a watch which suits for young generation in different occasions.
Visual reference
Primary research
Secondary research
Evaluation
Ideas
Word bank 5
Build test,iterate
Idealation
Build test,iterate
Opportunity areas
Theme
Cluster topics
Insight
Rip the brief
Ideas
Build test,iterate
Introduction Persona Observation Experience map
prorotype role play co-design
Idea Sketch
PERSONA
A user persona is a representation of the goals and behavior of a hypothesized group of users.
Goals: A device can help him use time more efficiently in dailylife Goal: A device can help him use time more efficiently in dailylife Task: Use wearable technology remin him the time and Task: Use wearable technology totoremind him theschedule time and schedule | Personality Open minded Responsible Efficient Balance life and work
Jam's bag is Millican -simple appearance -multifunction -size adaptable -2 hiding bags -adjustable supporter -prise ~$80
Exercise Jam likes outdoor sports, such as football, running, and weight training exercise.When he do exercise, he need to bring his phone very carefully or lock it on the locker.
Likes -simple -digital -fashion -neutral -professional -classic
Function -time -date -alarm -email -agenda -exercise recording
Dislikes Budget -big 50~100EUR -complex -hard material
Operation behavior Jan said once he had a watch, he will wear it all the time while he take a shower or go to bed. He hopes he can change its watchband for different occasions.
shower
Jam's smartphone is iphone4 -tiny -multifunctional -easy operation -fashion -portable -quality
Jam is an 22 years old post graduated student who comes from Netherland
| Motivation Jam is going to find a job, and he hopes he can look more professional and have a good time manage skill | Habit He thought the watch is not necessary. He said that wearing a watch will make him feel the sense of restraint. He usually takes his iphone4 all the time. To get email, check time, and communicate with friends. However, there are some special ocassions where are not suitable to check on his phone.
class
rest
meeting
study
exercise
alarm
| Typical Day
6a.m.
dating dating check
9a.m. restaurant reservation 12a.m. wake up breakfast
3p.m.
meeting remind
lunch
relex remind
6p.m. dinner
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Carolie counter
9p.m.
sleeping quality
12p.m. sleeping
OBSERVATION
The aim of the activity is to record and analyze user's interaction with the product.
Time checking-shaking hand
message - write
Time checking - watch wake up
message - phone get
function menu
heart beating detaction
exercise - calorie
function selection
top of watch
back of watch
reading message 7
phone speaking
EXPERIENCE MAPS The aim of the activity is to record and analyze user's interaction with the product.
TESK TIME CHECKING
ALARM CLOCK
MESSAGE
EXERCISE
PHONE SPEAKING
USE ANALYSIS
DOING
FEELING worry
THINKING
OPPORTUNITY
• • • •
boring
Am I late to the dating? What's the nex schedule? I should go to relax. How many hours I have done this?
• work efficiently • schedule list reminded
unhappy
lazzy
worry
• I don't want to wake up. • I don't want to turn off the alarm.
• Do I set the right time? • voice control • alarm setting feedback
unsure unhappy
neverous
• should I reply the message soon? • The word is too small. • I am on meeting could you send later?
• message rating system • message reading function • silent mode
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worry
happy
showoff
unsure convenient annoying
• Will the watch brake out? • Cool, I get the daily goal. • I will tell my friends how
• I can not hear clearly. • I need to call for help
• real time physical condition • history record • sharing function
• wireless earphone • show the calling picture • show the system status
I work hard.
immediately. • What wrong with the system?
VISUAL REFERENCE
Visual references can stimulate your ideas and know what is original and what has been done before. Title: UIUX
Title: Feedback
SUBTITLE: the way to know your body Â
SUBTITLE: The way to help you to select the function you want
Description:
Description:
Give you some suggestion to help you know your body condition
An easy and institute way to interact with the wearable technology. It can learn by your operation and adaptive to your behavior
Insight:
Insight: Training can help the system learn your body language
Automatically detect your physical condition and give you suggestions
Title: material
Title: Wearable accessory
SUBTITLE: a thing can be portable or can be part of you and present you
SUBTITLE: water proof & soft
Description:
A kind of material which is light and soft to touch your skin to help users feel more comfortable
Description:
Insight:
Insight:
The appearance should be fashion/neutral/classic/ simple/professional
Like water soft and can shape different type
Cutting the pattern can help it be flexible
Free your skin and give it a Free your skin and give it a fashion fashion
It can have a extension body to collect or stand
The material can be shaped to suit to different surface
Change color as the image you choose
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Change color in different type of occasions
RE-BRIEF
Use word bank to select the words which relative to the theme and make a brief.
Word bank Function Operate: multifunctional | humanity | AI Material: intangible | free | comfortable | Flexible Feeling
helpful | encourage | habit creative | understand you
Appearance fashion | neutral | classic | simple | professional
RE-BRIEF
Design a product In simple fashion design style to assist young people manage their time effectively and supervise their physical condition feedback.Consider institutional operation and comfortable wearable.
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SKETCH IDEAS Idea sketches should develop base on the brief description. Idea explanation:
Idea explanation:
How to help people do exercise more efficiently and safely?
How to simplify the operation and make it easy to use on different occasions?
When doing exercise, it is useful to feedback real time physical condition, such as heartbea, temperature, blood pressure, water sufficient, breathing...
Module design can help user chang color, shape and customized. Users can choose different patterns and function by themselves to show their style on different occasions.
To supervisor these signals, the wearable technology will be design to wear in wrist, neck, arms and ears.
Idea explanation:
Idea explanation:
How to meet different customers needs?
How to manage your time more efficiently?
Watch can also be an accessory. The different way to wear it give you a different style. Modular toolkit helps users to choose their unique watch/ necklace.
Tomato clock - the time management technique created by Francesco Cirillo for a more productive way to work and study. it comprises of the following basic steps: 1. Decide on the task at hand 2. Set the Pomodoro (timer) to 25 minutes 3. Work on the task until the timer expires; Record with an X 4. Take a Short Break (5 minutes) 5. Every four "pomodoros", take a Long Break (10 minutes)
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SKETCH IDEAS
The aim of the activity is to give detail information about your design. .
watch cover
necklace watch
screen module
watch can hang on a bag
screen upside down
Desing a structure to protect the screen and make users can choose their prefer cover.
Design a wirelss charger which can put on watch and show the battery.
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Design a band module which can help customers easily change their watch band and can be weared as necklace.
The style watch kit: band, screen module, chain and charger.
PROTOTYPE
Experience model is the most intutive way to feel the product and demonstrate to people what the expectation about the product
Color and pattern are important factors for customers to choose on different occassions
Module screen covers give customers a lot of options to show their wearing style.
UI-standard function
UI-exercise function
cover module
band module
style watch
necklace module
UI-tomato clock function
UI Funciton
UI test
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charger module
ROLE PLAY
Role play is a method to put yourself in the position of your user and cultivate empathy with the users of your product or service.
MISSION
EXPERIENCE
FUNCTION
WEARABLE
1. What kind of color combination young generations are preferred?
• Rerely to wear a watch since a smartphone is enough.
• Time, weather, GPS are necessary functions
• Wearing a watch gave him a sense of constrained feeling.
2.What functions are young generations required?
• Planning to buy a watch for graduation gift
• The interface should be as simple as possible.
3.Do they like to wear a watch on the wrist or take watch as a personal accessory?
• Necklace is weird for him, but he liked the idea to hang the watch on his bag.
• The wood and Africa pattern band ook fashionable
• Allowing user to set reminding time can add to the tomatoes clock. • Instead of count on a machine he preferred to feel by himself. 14
CO-DESIGN
Co-design is a well-established approach to creative practice, particularly within the public sector
WHO
WHAT
WHEN
The watch is designed for young people who are going to finish his/her study and prepare to work.
It's a digital watch which can be worn in two ways: wearing on hand or wearing on neck.
There are three main functions can be selected.
• price should be around $40~50
• Some people like analog watch.
WHERE
WHY
HOW
Modular design can change the cover and band in different style and suit in different occasions, such as meeting at a office, doing exercise and hanging out with friends.
Wearing a watch and that make them uncomfortable. • Boys prefer to hang on a watch on their bag, while girls prefer to wear on neck.
The cover can be changed to push the orange button. • It's hard to go through the string to the watch.
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• physical condition feedback (exercise) • tomato time (working/studying) • standard (time/GPS/weather/message)
• The orange button shoud be hidden.
Function:
-physical condition feedback
The watch fits your style in everywhere
-standard function: -wirless power charging
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Introduction: The aim of the project is to establish a company and use design to gain a strategic competitive adventage. Our company - Mano wants to help those with little expertise, time and storage to still have a high quality living experience with a personal touch.
Logo Website Poster Toolkit
Questionnaire Primary research
Secondary research
DIY market research DIY company research
Ideas
Sharing economy
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Build test,iterate
Evaluation
Build test,iterate
Idealation
Build test,iterate
Opportunity areas
Theme
Cluster topics
Ideas
Insight
Rip the brief
SWOT PEST Poter five forces
Marketing research ESTIMATED SALES BY PRODUCT CATEGORY 2015 2000 1800 1600 1400 1200 1000 800 600 400 200 0
ÂŁm
Decorative
Homewares
Big ticket
Seasonal
DIY & materials
Other
Market development
Niche Market
Market penetration
Product development
New
Excluding the big ticket, the most sales come from DIY tools and materials then decoration which Mano will be providing.
Markets
Most DIY companies focus their products on buying or renting business. However, Integrate all resources together in a proper way is important. Finding right tools and materials are hard for beginner users.
Existing
Mano is in the Product development phase. In the beginning, will target on the DIY beginners and offer them more powerful and integrate DIY toolkit. DIY pack is based on the DIY project. Tool, material and teaching video are all included.
Existing
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New
Products and Services
Sharing economy
The circular economy concept is a response to the aspiration for sustainable growth in the context of the growing pressure of production and consumption on the world’s resources and environment. As a new company, MANO has sustainable development strategies. Therefore, circular economy for MANO is a significant opportunity to expand our horizons. So we can grasp opportunities to extend product lifetimes and create competitive products that will last
The Access Economy seeks to minimize the demand for materials. The Access Economy is focused not on managing material at end-of-life, of better managing ‘waste’ To enjoy the progress of DIY itself , Mano supplies the service “too box-to-rent”, and help people save money and work efficiently on their DIY project. It is also environmental friendly, since renting service reduce the waste of materials which people do not need to possess permanently. 21
LOGO DESIGN
‘Mano’ means hand and it is to give you a helping hand!
The text is bold and surrounded from a frame to highlight it. The colors used are two shades of blue, which gives feelings of trust and productivity.
The leading color is a warm orange giving the idea of a fun and creative environment.
The symbol has been taken from the sign language symbol for help!
The logo is a thumb up, which represents the fun, with an open hand above it to show we can help enabling your creativity. Overall, the contrast of the colors makes the brand recognizable and easy to remember to the customers.
Slogan
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COLOR MATCH
The photos of made furniture from the packs will be uploaded and the colour ‘grabbed’ from them and added to the palette. Once all the colours have been identified the colour matching can begin Our software will scan the 1000’s of colour combinations within the system to generate a suitable paint selection. We will recommend the purchase of our paint pack with the paint.
The Mano characters have been developed to build up brand awareness. The superhero characters illustrate the company goal to help people experiencing the “power” of their own creativity. Mano box sets have been thought as an useful tool to reach that purpose.
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PRODUCT DESIGN
hobbyists
customer journey
Mano packaging is exclusively designed for the company and made entirely from 100% recycled cardboard. One of the main goals of the service is the reduction of material wastage. The design is extremely simple and straightforward, to keep usage as easy and accessible as possible. The communication is mostly based on images, so that customers can quickly get information about what it is inside the box and not spend too long reading instructions.
new homeowner
Start up designer
youn audit renter
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UI DESIGN - HTML / CSS / BOOTSTRAP
The “how to guide� helps you DIY your house, and also supply different tools to buy or rent
The community is a place for users to post their finished work for others to see.
The tools/materials/packs and videos have been separated via the categories the user may search for. The website design by Responsive web design (RWD), which allows desktop webpages to be viewed in response to the size of the screen or web browser.
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BUSINESS ANALYSIS
Augmented Product:
• • • • • •
Location: is flexible as Mano utilises the benefit of popup shops in order to gain market awareness, in busy cities e.g. London, Birmingham. Technology platform: well presented website and app. Differentiated: from the big competitors by renting out small medium size tools and selling packaged materials for tasks in the right qualities. Access: users can try our new materials and equipment. Inspiration hubs: pop up shop layout with expert advice and how to videos online. Social network: connecting DIYers and encouraging creativity in the community.
• Limited physical access: have only small numbers of popup shops in the city, may not be in the same place. • Small revenue streams: in comparison to the big players, hence require premium pricing. • Safety: cannot guarantee safety of customers during the use of equipment. • Short product lifecycle: equipment depreciation, fast technology advancement. • Easy to imitate: by other companies. • High equipment costs: for start up.
S W O T
• Market leader: in the niche market targeted for the small medium size household. • Recycling/refurbish: of materials. • Low barrier of entry: as niche targeted. • Intellectual property: for brand name. • Community: building and sharing experience. • New technology: uses of tech (e.g. IOT) and materials to explore such as augmented reality and eco friendly materials. • Flexible: ability to tap into the renter’s market in terms of quantities provided and ideas for decoration from how to videos. • Business networks: with new business opportunities e.g. digital fabrication businesses (use of 3D printers for decoration).
• • • •
Physical hub
Website
Promotion
Core product: Accomplishment, Self affirming, Inspiration, Creative
Mobile Access
Expert advice Virtual Reality ‘Shopping’
Intellectual property
Free sign up
Insurance
Secure payment Customer service
P • Political uncertainty: Brexit poses a risk to the current political environment. There is uncertainty in regards to the direction the UK will take in order to stabilise the markets and consumer confidence.
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Packaging
Support
Tool & material providing
•
Competition: intense competitors from the shed and big box retailers, still have a big market share. • Legal: risks, health and safety. • Theft: of physical equipment, cybercrime. Charges repair: to the customer if broken, may reduce return rate. Inflation: of materials and tools. Cash flow: need to pay particular attention to cash flow as equipment are being rented, Mano have limited supply. Technology advancement: require to stock up on the latest equipment which will cost.
Colour Matching
Actual Product:
Community
E • Weak Sterling: Due to the weak sterling post brexit, this will likely fuel inflation of prices, as imports becomes more expensive including fuel, transport and import of raw materials. • Housing Market: Despite brexit the housing market is holding up steady, this may have been influenced by the Bank of England cutting interest rates to the base of 0.25%. • Mortgage rates: Due to this, it is making mortgages cheaper for home owners.
S • Network: Connected world through the internet of things. • Shift to renting apartments: 25-34-yearolds are now twice as likely to rent private accommodation in comparison to 2004.
T •
•
•
Internet of things: Give many opportunities to communicate and engage end users. 3D printing: Are becoming readily available, opportunities to create personalised home objects. Fast past innovations: In technology e.g. augmented reality, are giving more user experience to engage the user.
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Introduction: The aim of the project is to design a modular wheelchair which give users maximum choice and enable them to tail their wheelchair to their body, lifestyle and Environment?
Wheelchair in developing country
IDEA SKETCH
CAD model CAE analysis
wheelchair user interview Primary research
Secondary research
Ideas
Ergonomics Demographics Postural support device case study- modular design case study- NGO case study- Uganda
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Build test,iterate
Evaluation
Build test,iterate
Idealation
Build test,iterate
Opportunity areas
Cluster topics
Theme
Rip the brief
Insight
Existing products Perception Modular Material Manufacturing Services Ergonomics Demographics Market Laws
Ideas
RESEARCH & INSIGHT
20 million
people in developing countries require wheelchairs
Problem Many developing countries have very little capacity to produce wheelchair and mostly depends on foreign donation, which are of poor quality, not tailor-made for the requirement of the user. They are unable to work because of the lack of unavalibility(WHO,2006)
1%
There are many reasons why someone would need to use a wheelchair. Some of the most common causes include old age, severe weakness, muscular and skeletal disorders, neurological conditions, congenital anomalies, spinal cord injuries, and other infirmities. The most common cause known is Spinal Cord Injury caused by a motor vehicle accident. Some disease patients, such as cerebral palsy, stroke, polio, spinal cord injury can not balance their body. In that case, they need PSD to support their body.
Below of their need is being met in Africa by local production Solution before - PSD
Motor vehicle accident
Other or Unknown
However, PSD needs professional assessment and give product prescription. Traditional process (use ruler to measure) is time consuming and inaccurate. In addition, some wheelchair think PSD does not look good and makes his/her disability more obvious.
8.2%
9.7%
39.2%
3.3% TBI Arthritis
Sports
3.9% ALS
6.3%
13.3% Cerebral Palsy
15.6%
Spinal Cord Injury
4.5%
CA
The improper sitting posture may cause pressure sores, deformities of the spine. How to adapt wheelchairs to meet users needs is the key of the problem. Postural Support Devices(PSD) are customized to help wheelchair users adapt their wheelchairs.
Disadvantage of the solution
US ES
28.3% Falls
14.6% Acts of violence
DIAGNOSIS
18.8% Miscellaneous
Other
23.2%
5.9% Stroke/CVA
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COPD
5.3% Multiple Sclerosis
RESEARCH & INSIGHT
RESEARCH & CASE STUDY
Many developing countries have very little capacity to produce wheelchair and mostly depends on foreign donation, which failed to meet individual needs. (WHO,2008)
demographic
human factors
PSD
open source,modular
local service
local factory
• Imprecise and ineffective measurement • Local factories lack of knowledge about PSD • Service personnels are shortage • Developing countries lack of proper wheelchair service system • Open source wheelchair parts are already exist, but they lack of integration
Donation wheelchairs
PSD (postural support device)
• do not fit body size • do not fit environment • can not tailor • difficult maintenance
ABANDON
SUITABLE
In a survey of 147 users conducted at the Western Cape rehabilitation Centre in South Africa in 2006, it was found that 58% of users required some form of wheelchair modification or basic postural support. Some 22% required complex postural support, while only 20% were able to use a basic manual wheelchair without any modification.(WHO,2008)
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Re-Brief Design a system which can integrate local wheelchair services, factories and wheelchair open source database to help users easily select and customize their wheelchair PSDs(postural support devices) and accessories.
Local Manufacturing
Easy Maintenance
LOCAL WHEELCHAIR SERVICE CENTER
• Who is customer • How to meet user needs • What people want to customize • How to supply proper wheelchair service • What to measure • How to measure
LOCAL FACTORY Good FIT SYSTEM
Precise Measuring
Good Matching
OPEN SOURCE
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• How to reduce the cost • How to maintain easily • How to install easily • How to be sustainable • How to check the quality • How to reduce the entrance barrier
• How to help wheelchair users select proper PSD • How to supply more interaction experience to user • How to integrate the existing open source resources
IDEA SKETCHING The idea shows the mechanism measuring device.There are some features should be careful design: 1.The position of laser projector device -How to make it more easy to operate? 2.The seating box material and size -All the human body weight center will applied on the seating box. 3.The mechanism and dimension of measuring bar -The device should be used in different body size but also easy to carry.
Design a device can measure human body size and wheelchair size
IDEA sketching
Create parts and assembly 3D models
seating box design analysis(size/material) device operation analysis
CAD computer-aided design
CAE computer-aided engineering NO
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YES
operation and storage process
Render Animatation
EVALUATION - FEA Aim: To make sure the seating box is strong enough to support the human body weight
How: 1.Set the parameter - thickness of the seating box chair 2.Input the condition : fixture and load (2000N) 3.Set the material : Acrylic 4.Run the simulation
Tab 1. model information
Tab 2.model information
t
Fig. 1. stress analysis
Fig. 3. parameter setting
Fig. 2. displacement analysis
Result and analysis: The highest stress is 8.652 Mpa, and it happen on the corner of the seating box (Fig. 1) The highest displacement is 3.194mm, and it happen on the center line of the seating box(Fig. 2) To optimize the seating box, we input parameter t (Fig. 3) and set the max displacement is around 1mm The thickness of the seating box changes from 5cm to 6cm (Tab. 3) 34
Tab 3. optimization table
EVALUATION - JACK Aim: To simulate different posture while operating and reduce the risk to get injured How:
1.Create virtual human and set the condition 2.Control the human body to the specific position 3.Run the back force simulation 4.Run static strength prediction tool
Fig. 1. standing posture setting
Fig. 2. move the device
Fig. 3. back force simulation
Fig. 4. static strength prediction
Result and analysis: The compression of the L4/L5 force is around 1400N(Fig. 3) The moment of the L4/L5 force is around 70N(Fig. 3) Most of healthy people have enough strength to operate the device(Fig. 4). The new design change the laser sensor to the back position. Operator can easy to control and read the dimension of mark in standing posture. Compared to the old design, the L4/L5 force changes from 2800N to 1400N and the moment changes from 120N to 70N. 35
SYSTEM FEATURES
K:Seat to base of skull E:Seat to bottom of shoulder blade F:Seat to top of shoulder D:Seat to bottom of rib cage I:Seat to top of pelvis B:Seat depth C:Calf length L:Back of pelvis to seat bones
human body size measurement
A:Hip width G:Trunk width J:Distance between knees
human body size measurement
extensible and moveable design
adjustable design to measure different angles
small medium
large
human body size measurement
wheelchair size measurement
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open source database calculates available space to install PSD
SYSTEM COMPONENTS
4 3
5 6
15
11
2
12 13 14 7
1
8
16 9 10
Exploded view 1
Perspective view 2
Seating box -ABS
Bottom slide bar -aluminum
5
6
Back extended bar -aluminum 9
Back adapter -aluminum 10
Calf measuring bar -aluminum
Calf extended bar -aluminum
13
14
Slide bar breaking -rubber
Slide -ABS
3
Folding design-easy to portable 4
Back slide bar -aluminum
Back measuring bar -aluminum 8
7
Thigh measuring bar -aluminum
Thigh extended bar -aluminum
11
12
Back angle adapter -aluminum
Back adjusting knob -aluminum
15
16
Laser projector -Red-ray laser diode
Calf angle adapter -aluminum
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Patch for laser positioning
Laser projector
38
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Redesign - heater
Introduction: The aim of the project is to improve the Beldray heater and redesign the heater, which is in compliance with sustainable design.
SimaPro
Okala Ecodesign Strategy Wheel
CES EcoAudit
Ecodesign check list CES material
EcoDesign radar SimaPro CES EcoAudit Material selection 5 4 End of life
3 2
Material usage
1 0
Optimal life
Distribution
Product use
Primary research
Secondary research
Ideas
41
Build test,iterate
Evaluation
Build test,iterate
Idealation
Build test,iterate
Opportunity areas
Theme
Cluster topics
Insight
Rip the brief
Ideas
PRODUCT FEATURES & COMPONENTS Scope&System boundary
The electric heater is portable and easy to use. It includes outside and inside components. The system boundaries exclude the packaging, plug and screws. Since most of these components are standard and the report will more focus on the heat transfer and operation process. Besides, the report do not consider automatic constant temperature function. All the calculation uses max energy 480W/hour.
Function unit
To define function unit can help me to compare different production that deliver similar performances. heat transferred (W, Btu/hr) in the space 3m*3m*2m for 6 hours a day*30 days a month * 4 months a year * 2 years =1440 hours
NO 1 2 3 4 5
Power Rating: 450W Life expectancy: 2 years Estimation of energy per lifetime: 450W * 1440hours *3600s = 2332MJ
6 7 8 9 10 11 12
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component Removable feet Air intake left Air intake right Hot air outlet Mounting bracket back Adjustable temperature control dial
material ABS ABS ABS aluminum aluminum
Weight(g) 11 58 54 207 227
number 2 1 1 1 1
ABS
3
1
Nickel alloyďźš Cr20Ni80,Cr15Ni60,GH140
62
1
Big conduction protector ABS Small conduction protector ABS Inner Electricity wire copper alloy -145cm cable Plug cover ABS Screw stainless steel
59 5 137 33 15
1 1 1 1 1
Conduction
LIFE CYCLE ANALYSIS - SimaPro
Fig. 3. Analyze the impact of the heater along its life cycle
Fig. 4. Identify the environmental effects which are responsible for the highest contributions
In figure 3 shows that the major energy consumption is in the use phase. The impact of use phase is 8.6 times than pre-production and production phase. There are three main factors in SimaPro: Human health, Ecosystem quality, resources depletion. In figure 4 and figure 5 show that inner electricity wire(Cu), thermal conduction(Nickel alloy) and mounting bracket back (alumiunm) have main impact on human health. We can think about to use another material to replace.
Fig. 5. Identify the processes/materials responsible for the highest contribution to the impact
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LIFE CYCLE ANALYSIS - CES ECOAUDIT
Fig. 6. The heater's energy consumption in different stages for 2 years
Fig. 7. The heater's CO2 footprint in different stages
In the SimaPro analysis we find that the annual energy consumption is around 2490MJ/year, and the amount of energy is equivalent 260 kg CO2(figure 7).The most of energy consumption is in use phase(figure 7).
50 45 40 35 30 25 20 15 10 5 0
The static use energy(2490MJ/year) is different from estimation before (1166MJ/year) since of diffrent country electricity mix. In Europe, Energy equivalence is 2.07 (MJ/MJ) and half of the energy comes from fossil fuel transformation (figure 2-1) The product efficiency of electric to thermal is around 1
In figure 8 shows in pre-produciton stage most of energy cnsumes in the aluminum cover. Therefore, we can think about how to replace with other materials.
Fig. 8. pre-production material energy consumption(MJ) 44
QUALITATIVE ANALYSIS priority level
Reduced distribution impacts
Reduced behavior and use impacts Reduce energy during use Design for carbon-neutral or renewable energy
Manufacture innovation Seek to eliminate toxic emissions
System Longevity Design for maintenance and easy repair
Reduced material impacts Avoid materials that damage human or ecological health Minimize the quantity of materials Use recycled or reclaimed materials Use renewable resources
Transitional system
Innovation Optimized end-of-life Use recyclable and non-toxic materials Fig. 13. Okala Ecodesign Strategy Wheel 45
Design for upgradable products Design for second life with different function Provide for reuse of components
REDESIGN - MIND MAPPING
Fig. 14. Redesign idea development Reduce energy during use
Behavior change
Design for second life with different function
Reduce material impact
1. auto temperature control 2. auto switch off 3. increase the convection ex: adding motor fan 4. use renewable energy to supply the power 5.timer control
1. show the electricity price 2. show the red LED light to remind users turn off the power
1. can also be used like normal fan to cool down the temperature
1.replace the aluminum cover 2.replace the Nickel heat conduction 3.use less screws
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REDESIGN - RESEARCH The heat transfer per unit surface through convection was first described by Newton and the relation is known as the Newton's Law of Cooling (Engineeringtoolbox.com, 2017) q = hc A dT q = heat transferred per unit time (W, Btu/hr) A = heat transfer area of the surface (m2, ft2) hc = convective heat transfer coefficient of the process (W/(m2K) or W/(m2oC), Btu/(ft2 h oF)) dT = temperature difference between the surface and the bulk fluid (K or oC, F) hc = 10.45 - v + 10 v1/2 Note! - this is an empirical equation and can be used for velocities - v - from 2 to 20 m/s v = the relative speed of the object through the air (m/s) (normal fan speed around 5m/s) heater without fan hc is around 7.9(W/(m2 K)) heater with fan hc is around 27.95(W/(m2 K))
The Positive Temperature Coefficient (PTC) thermistor is also known as PTC resistor, a treated Polycrystalline ceramic based on barium titanate (BaTiO3). Specific treatment procedures provide that one can obtain high conductivity in the material at relatively low temperatures (Dxmht.com, 2017). Typical features of (PTC) )heaters: • Uniform heating without power variation • Control of the thermal power through the airflow • Long life • Self-regulating function • Fast warm-up
hc: the heater with fan = 3.5 times the heater without fan
Fig. 17. PTC heat conduction (Dxmht.com, 2017) Fig. 16. Air - heat transfer Coefficient (Engineeringtoolbox.com, 2017)
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REDESIGN - MATERIALS SELECTION Material conditions: Price 1~3 GBP/KG Young's module 2~3GPA Yields strength 29~45MPA Maximum service temperature 100~300 C In figure 15 shows the dstribution of different materials through max service temperature and CO2 footprint in primary production.
Why choose PP? To replace Aluminum cover, the material need to has high temperature resistant. Although PF has the highest service temperature, it is not recyclable and can only be manufactured by casting. Compared to SMA, PP has less CO2 footprint and the price cost less. The service temperature is also higher than ABS.(Table 3)
Fig. 15. CES material comparison
Material
ABS
SMA
PF
PP
Young's modulus(GPA)
2-2.9
2.34-3.42
2.76-4.83
2.06-2.27
Maximum service temperature(°C)
62-77
102-117
142-157
80.6-103
Thermal conductivity(W/m.°C)
0.226-0.235
0.16-0.18
0.141-0.152
0.127-0.132
CO2 footprint, primary production(kg/kg)
3.45-3.81
4.3-.475
4.74-5.23
3.63-4
Recycle
YES
YES
NO
YES
manufacturing
extrusion
extrusion
casting
extrusion
Price(GBP/kg)
1.75-2.1
2.8
1.23
2.06-2.27
Tab. 3. The comparison 48of different materials
REDESIGN - CONCEPT ANALYSIS
concept1: The design has a great heat convection, but it also consumes more materials and the shape limit the function.
concept 2: The design is simple and the affordance is more stronger, which has a intuitive operation.
Material selection 5
Material selection 5
4 End of life
3 2
Material selection 5
4 Material usage
End of life
3 1
0
0
Distribution
Product use
Fig. 18. concept1 EcoDesign radar analysis
4
Material usage
2
1
Optimal life
concept 3: The design is similar to second one; however, the fan's shape can speed up the velocity of the air more.
End of life
3 2
Material usage
1 0
Optimal life
Distribution
Product use
Fig. 19. concept2 EcoDesign radar analysis 49
Optimal life
Distribution
Product use
Fig. 20. concept3 EcoDesign radar analysis
FINAL REDESIGN - FEATURES
3
4
Reduce material impacts for human body: • The cover of the heater made of PP material. Replace the original material - aluminum • Reduce the components such as removable feet, screws
Module design: • Easy to maintain • Fan and Heat conduction can take apart easily
1 Reduce energy during use: • Add fan to increase the convective heat transfer coefficient, which allowed higher function unit in the same space • The material TCP heat conduction has high efficient to generate heat
2 Reduce energy during use: • Showing real time temperature • Auto switch off design to save more energy • Temperature setting • Real time message feedback such as operation time, error
5 Design second life with different function • The heater can switch from hot air to cold air in different temperature. Fig. 21. The features of the redesign heater 50
FINAL REDESIGN - COMPONENTS
2
Positive Temperature Coefficient (PTC)
4
6
5
8 1
10 9
7 12V,0.3amp, 3.6w/hr
3 Fig. 22. The exploded view of the redesign heater
Feature: The redesign heater's heat conduct material will change from Nickel alloy to PTC which has high efficiency and longer life. The redesign heater also select PP material to replace aluminum, it will be less harmful to human body during manufacturing. Additional motor fan will be installed to increase the heat transfer efficiency.
NO
component
material
Weight(g)
number
1
Heater body
PP
643.33
1
2
Hot air outlet
PP
62.66
1
3
control panel
PP
6.9
1
4
Conduction
TCP
62
1
5
Conduction protector
PP
2
1
6
Fan cover
PP
17.28
1
7
Fan
PP
31.67
1
8
Fan motor
20% copper and 80% steel
52
1
9
Inner Electricity wire
copper alloy -145cm cable
137
1
10
Screw
stainless steel
10
1
51
PROJECT - RB
52
PROJECT- BRADY
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THREE-AXIS ROBOT ARM
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THREE-AXIS ROBOT ARM Robot Arm Design -the robot can play chest with you
Topic:Mechanical Product Design Completed: 2008 The Brief: This product is designed to play GO with elderly people, so that they will not be bored. The robot arm has a 3-axis motor which can move synchronously and pick up the game pieces automatically. The design considers the center of gravity and functionality of motors.
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FIVE-AXIS CNC MILLING TURBINE BLADES -use CNC to mill the turbine blades
Topic: Manufacturing Design Completed: 2010 Brief: This product was part of my master’s thesis, and uses an engine to generate power. The process involved design (CAD), generating the tool path (CAM) with RHINO, and then milling the shape using a 5-aixs CNC.
CAD- Sketch in 2D
CAD-building model in 3D
CAM-simulate cutting
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CAM-simulate cutting
THREE-AXIS CNC MILLING GOLD BEACH -use CNC to cultivate the nurbs line
Topic: Manufacturing Design Completed: 2012 Brief: This craft is composed using NURBS lines, and is shaped like a wave on a beach. Under the yellow light bulb, the color looks like a sunset. The process involved design (CAD), generating the tool path (CAM) with RHINO, and then milling the shape using a 3-axis CNC.
CAD- building model
CAM- setting of tool path
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CAM- CNC code
HANDCRAFT - WOOD AURORA -a toy can project the aurora in your room
Topic: Toy Design Completed: 2013 Brief: This toy was made using waste wood and CDs to remind people to protect the environment. Due to the greenhouse effect, many wild animals are disappearing. When you turn the handlebars, the LED will project like an Aurora, and the penguin's angle determines the height of the light reflected off the CD.
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HANDCRAFT - WOOD WALKING DUCK -A toy can imitate the duck walk
Topic: Toy Design Completed: 2013 Brief: This toy was made using waste wood and produced using a lathe.Users can make the duck walk by turning the handlebars to compress the spring.
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UI DESIGN CNC UI -3axis CNC controler HMI design
Topic: UI Design Completed: 2014 Brief: This HMI was design by .NET and used for CNC milling machine controlled by touch pannel and key board. The ICON and specific color could provide intuitionistic and visual assists for software operators.
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MARKER SKETCH
61