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BA Hons Product Design.Technical report.
Dremel Airwave 800.David Carr. April 2015.
Summary.
The main basis for this project revolves around the tasks that are regularly undertaken by DIY/hobbyists; to develop a solution to reduce health risks and improve working conditions in these environments. When people undertake tasks at home such as soldering, sawing, sanding and filing, the majority of people do non’t the proper safety precautions and may be putting their health at risk. When soldering gasses and fine particles are emitted into the air which can cause a number of long term respiratory problems; with similar effects being caused by other tasks that produce fine and sub-micron particles.
The main aim of this project was to develop a product that would be effective at dealing with the fumes, fine particles and heavy debris that are common in a DIY/hobbyist working environment. To achieve this the designs were developed through physical prototyping and testing to develop a function driven product with sufficiently proven functionality.
The goal of this project was to produce the concept for an innovative product that would sell in the current competitive market, but have reduced running and maintenance costs respective to the alternative options. With an active and exploratory approach to design a solution has been produced that delivers a number of desirable features to the end user of the product whilst still delivering the core functionality of improving the working environment and relative health of the user.
Contents.
1.0 The brief. 1 1.1 Project scope. 1 1.2 Key deliverables. 1 1.3 Interpretation of the brief. 1 1.4 Rational. 1
2.0 Specification and constraints. 2
3.0 Design method. 3
4.0 Research and design strategies. 4 4.1 Target market. 4 4.2 Harmful fumes and particles. 7 4.3 User requirements. 8 4.4 Task Analysis. 9 4.5 Unique selling points. 10 4.6 Competitive products on the current market. 11
5.0 Design development. 12 5.1 Initial concept. 12 5.2 Second and third prototype. 15 5.3 Fourth prototype. 16 5.4 Fifth prototype. 19 5.5 Fifth prototype modifications. 21 5.6 Sixth prototype. 23 5.7 Seventh prototype. 26 5.8 Designing around the functionality. 30 5.9 A redesign to allow for human factors. 32
6.0 Design solution. 35 6.1 Description and justification. 35 6.2 Visual aesthetics. 38 6.3 Airflow and separation methods. 39 6.4 Variable suction. 41 6.5 Auto start line out feature. 42 6.6 Removing and emptying the bins. 43 6.7 Omni wheels. 45 6.8 Storage. 46 6.9 Retractable cable. 47 6.10 Changing the active carbon granules. 48 6.11 Default intake tool. 49 6.12 Materials, manufacturing and main components. 51 6.13 General arrangement. 53 6.14 SWOT analysis. 55
7.0 Conclusion. 57
8.0 Bibliography. 59
9.0 List of illustrations. 60
10.0 Appendixes. 61
1.0 The Brief.
1.1 Project Scope.
This project required a new fume extractor based product to be produced for Dremel and designed to be competitive on the current market. The product needed to have proven core functionality and be developed with the aid of research and physical product testing. Ultimately a viable design concept would be required as a set of CAD data that could considered for production.
1.2 Key deliverable elements. • CAD data for individual parts and assemblies for the finalised design. • Fully considered and functionally developed design. • Technical and supporting project data.• Presentation boards along with a physical project presentation.
1.3 Interpretation of the brief.
The project will involve a number of practical prototyping and testing elements to create prototypes based off initial research and con-cepts. An understanding of all of the forces in play will need to be developed through analysing prototypes and how changes to design affect the products performance. The core elements of the design will need to be developed in this way, but the outer casings for the product should be considered for human and environmental factors. The finalised design should be developed and styled to fit in with the current Dremel product range and be competitive on the current market. For further details please view the product brief document in appendix 1.
1.4 Rational.
The proposed Fume extractor/vacuum cleaner based product will be developed in a sympathetic way to the DIY/hobbyist tasks that it is designed for, to best allow it to be used to reduce the health risks from fine particles and fumes in the intended environment.
2.0 Specification and constraints.
• The finalised product should be designed for mass production by Dremel. • The design should be reviewed by qualified designers at various key points through the project to ensure that it is true to purpose and the consumer’s requirements. • The product should be value engineered to reduce the tooling and production cost for the product, allowing for a better retail price to the consumer and a competitive price point on the current market. • The environment that the product will be used in must be considered and adjustments made to the design where necessary to accommodate environmental constraints. • The product will need to be versatile enough to cater for a wide range of different tasks that require extraction. Overlaps in the markets between a fume extractor and vacuum cleaner are encouraged as it would provide a more functionally applicable product for the current Dremel range.
1. 2.
3.0 Design method.
This is a basic view of the design process that was applied to the Dremel Airwave 800 project. As the project was so technically based and required a product with a proven and viable design, there was particular emphasis placed into the 3D prototyping and incremental development stages of the process.
The design process started with research into the problem areas as well as researching into the target market and the type of tasks that DIY/hobbyists would be undertaking. Once a solid understanding of this and the core requirements that the product would need to fulfil were built up, early viable designs were then built up around the insight from different turbine based separation methods.
Much of the design process was taken up by 3D prototyping of ideas to then develop upon the designs through a number of prototype iterations until a working prototype had been produced with its functionality proven.
Once the core functional elements were completed, ergonomics and other human factors were developed into the design along with product and environmental constraints to produce a finalised and agreed upon design.
4.0 Research and design strategies.
4.1 Target market.
Dremel’s target market.Dremel markets itself to a very wide target market as of their versatile products and vast product range including most handheld tools from glue guns to full compact multitools and mechanical coping saws. The main target age range is roughly between 18 – 50 although some of their tools are appropriate for other ages with the correct knowledge and ability.
Dremel products are mainly workshop or DIY/hobbyist tools and are both designed and manufactured to a high quality to produce a long lasting product. The tools produced are well suited for small and intricate work but can cope with some larger jobs. The type of person to use a Dremel product would most likely be a skilled or semi-skilled ‘craftsperson’ working on a small job from engraving glass to sculpting metal and wooden forms.
The range of Dremel tools and bits for their products also allow for almost any material to be worked with effectively allowing a user to work easily on items such as jewellery.
4. 3.
http://www.dremeleurope.com/gb/en/
Dremel also gives clues to its target market with a range of online booklets and brochures available on their website. These feature a large range of DIY tasks that can be done around the home and garden, demonstrating the tools and their applications. These brochures commonly feature youthful DIY/hobbyists in the marketing imagery to best apply to the younger side of the market.
Dremel Airwave 800 target market.
The Dremel Airwave 800 is designed to encompass much of the same target market as above, however it is targeted more at the people who might be using tools such as the Dremel soldering irons, flame torches, multitools and other fine working tools. The extraction system at the core of the product is able to cope effectively with the fine particles and fumes given off by these products to remove particles from the air and neutralise gasses.
The product would be best suited to a DIY/hobbyist working in a small room or workshop as of its miniaturised and compact design. The product is able to cope with larger debris and volume of dust associated to larger work in a full sized workshop but is targeted more towards the smaller scale of working.
5. 6.
http://www.dremeleurope.com/specials/book-of-inspiration/gb/en/
4.2 Harmful fumes and particles.
There are a number of health risks that come from working on tasks that produce fine particles and gasses, and it is common for most people to be unaware of the type of harm that the particles could be doing to their health.
Purex fume extraction systems is one of the industry’s leading manufacturers of industrial fume extraction products and services. They have carried out a number of studies and confirmed a number of health risks with direct correlation to being exposed to fine airborne particles and fumes.
Listed in these tables are just some of the material emissions and risks that a DIY/hobbyist may commonly be exposed to.
4.3 User requirements.
• To remove most of the health risks associated with fine/sub-micron particles and gasses in the air the end user will require a product that can provide a good level of strong extraction. • With the extractor being used for extended periods of time it will need to be relatively quiet (especially as some users may be working by hand only) and cope with long runtimes without overheating. • An energy efficient system needs to be developed to reduce energy consumption. • As the user may well be working on small and intricate parts (possibly held in the hand whilst working) it will be necessary to be able to reduce the amount of suction at the inlet to prevent the work being taken into the extractor.
7. 8.
http://www.desso-airmaster.com/en/home/business/desso-airmas-terr/reducing-fine-dust-in-the-breathing-zone/
http://www.purex.co.uk/fume-extraction/examples-of-hazardous-fumes/
4.4 Task analysis.
The Dremel Airwave 800 would be used for a range of tasks within the DIY/hobbyist environment, however the main tasks can be put into the categories of soldering and fine work, working with power tools and cleaning up.
Soldering and fine work.
When soldering and using the extractor on fine work, the extractor will need to be able to sit directly onto the desk where the work is taking place with an effective intake nozzle attached. The extraction level would need to be adjusted to be appropriate for the current task to take away fumes and dust without affecting the work that is being done. When soldering a good level of light is required and a magnifying glass set up may be used so the extractor needs to be effective when it is not positioned above the work. Fine sanding and filing work may similarly require the extractor nozzle to be placed to the side of the work.
Working with power tools.
When using power tools such as the range of Dremel multitools a large volume of fine/sub-micron particles can be produced very quickly and become airborne. There are already a number of tools on the market that fit onto a multi tool on a vacuum system to take away the particles which can be used in this scenario. When the task is being carried out it is possible that even though everything is connected, the user may simply forget to activate the extractor as well as the power tool, and it may be cumbersome with the need to activate two separate devices.
To solve this problem and improve the users experience the Dremel Airwave 800 has been designed with an ‘auto start line out feature’ where by upto 2 power tools at a time can be plugged directly into an extractor. When the power tool is switched on the extractor detects a draw in power and automatically starts up the extraction to the power tool or other attachment in use.
Cleaning up.
The Dremel Airwave 800 can be used as a conventional vacuum cleaner for the task of cleaning up in a DIY/hobbyist environment. With a number of attachments available and a flexible hose the extractor can clean large surfaces and into tight spaces. The extractor also features multi-level separation to allow the potentially toxic fine and sub-micron dust to be emptied from a separate bin to the larger waist, preventing it from becoming airborne.
4.5 Unique selling points.
The Dremel Airwave 800 features a number of different USP’s, the most notable of which is that a fume extractor and workshop vacuum cleaner have been merged into one product. Other features include:
• Separate high and low pressure collection bins. • Low pressure bin auto fills from the back due to airflow channelling. • Self-cancelling cyclonic shear in collection bins to minimise energy loss. • High pressure separation to remove sub-micron particles prior to active carbon filtration. • Active carbon filter with manual carbon replacement option. • Auto start line out feature. • Variable suction control.• Inbuilt 3 metre cable.• Compact design.• Self-cleaning turbine.
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4.6 Competitive products on the current market.
There are a number of products currently on the market that do a similar task to the proposed product in terms of either a fume extractor or a dust extractor/vacuum cleaner. Although these are successful options in their own right they have problems when they are applied to the small working and smaller working environment associated with the DIY/hobbyist environment.
5.0 Design development.
5.1 Initial concept. At the start of the project an early concept was drawn up based off the project requirements and the understanding gained from research. This concept was shown to a number of professional product designers prior to fully committing resources to the project.
11. 12.
The design was based around using a tesla turbine as the basis for the impeller and separation system as of its ability to create high pressure boundary layers and lamina flow inside of a housing mount. If this could be successfully applied to an extractor and used in the proper way these high pressure boundaries would allow the harmful fine particles to be separated through high centrifugal forces.
With approval the first project prototype was drawn up based off rough sketches and the concept illustrations. The prototype was built up using laser cut cardboard and thin plastic.
Although the prototype was built to the way that a Tesla turbine was understood to work the prototype was unsuccessful in creating a vacuum. This could have been down to the design or a problem with the tesla turbine itself and further testing will be needed.
13. 14.
5.2 Second and third prototypes.
The second and third prototypes were built up in the same way as the first, and made specifically to test out the theories and try to see how the turbine was working. The second prototype created airflow however it was in the opposite direction to that intended.
The third prototype was built upon the new understanding of how the tesla turbine was working from the previous prototype. This new version was designed specifically to allow for in built venting and airflow channels to be opened and restricted to see the effect. Some light test dust was used to help visualise the airflow through the prototype and it was clear that the airflow worked best as shown by the diagram.
5.3 Fourth prototype.
The fourth prototype was designed based off the prior testing and analysis of the previous prototypes. The new prototype was designed to be more durable with incorporated bearings and was designed to accept a range of different turbines, fans, impellers and combination stacks for better testing.
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Over 11 different prototype configurations were built up and tested with the prototype whilest being recorded for later analysis. This prototyping gave a good insight into what was happening inside of the prototype and also allowed for a better turbine combination to be designed into further prototyping.
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5.4 Fifth prototype.
The fifth prototype was built upon everything learnt so far and some further research into turbines and impellers. The prototype saw an approximate 300% increase in suction and efficiency whilst still using the same axil rotation speed as previous testing. The prototype was put through a range of tests using fine test dust and was recorded to allow for airflow analysis to be carried out within the prototype.
19. 20.
5.5 Fifth prototype modifications.
Through altering the airflow and venting inside of the prototype it became apparent that by splitting the prototype into two separate elements and altering the intake pipe to be seated directly into the lower bin, the suction of the prototype could be again doubled. The simple modification to the prototype had a significant effect but also lead to the intake being less restricted.
With the intake now leading directly into a bin rather than the main separation element, a larger diameter intake could be used and larger debris can be vacuumed in with no risk to the turbine.
The design alterations also allowed only the fine particles to make it into the top of the separation cone and be expelled into the high pressure bin. This was a particularly notable development as it now allows these hazardous particles to be removed from the main containment but not permitted into the filtration element. As of this these particles can now be treat separately at the emptying phase to prevent them becoming airborne.
21. 22.
5.6 Sixth prototype. This prototype was based off a very similar design to the previous version but featured a more refined design and internal geometry. The prototype was also built up with a new turbine stack that has been mounted to a real vacuum cleaner motor with the intent of full scale prototype testing. For this reason the prototype has been developed to be more rugged and is arranged in a configuration more like a conventional canister vacuum cleaner due to the constraints on the prototype.
This prototype also features an asymmetrical low pressure collection bin with an intake nozzle off to an angle which should in theory fire the main bulk of the debris to the back of the bin as it enters containment.
23. 24.
This prototype was tested but the turbine and other parts failed during the first start up. 5.7 Seventh prototype.
This prototype follows the same design and the previous but features a 3D printed turbine and a reinforced high pressure bin and separation elements.
This prototype was put through full prototype controlled testing using a range of different test dust and debris. The prototype had a high level of suction and was able to cope reasonably well with the prototype trials.
25. 26.
Through recording and analysing the testing of the prototype it was clear to see that the cyclonic shear from the upper turbine was cancelling out the cyclone naturally formed in the low pressure containment bin. This reduces the overall amount of energy that is lost to moving airflow to increase efficiency, and also acts to ‘deaden’ the air flow to help heavy particles fall into collection.
Only the fine and sub-micron particles made it up into the high pressure collection bin where they remained and were restricted from exiting the product due to the internal geometry and centrifugal forces from the turbine.
The prototyping was now to a stage where all of the functionality of the product had been reasonably proven and the core functional elements could then be designed around to produce a viable design.
27. 28.
5.8 Designing around the functionality.
With the core functionality of the design finalised and the working elements tested up to acceptable working tolerances, the main design was worked upon to try and design in more of the human factors to the design. A casing would be required for the product that will cater to the DIY/hobbyist market and meet some of the task specific needs such as being relatively small, manageable and quiet.
29. 30.
The designs were developed through sketching with a rough concept model being created for peer review by fellow designers. Whilst the design was functional it did not fully meet the project requirements of the end user and also seemed to be configured in a way that is too much like a conventional canister vacuum cleaner.
5.9 A redesign to allow for human factors.
Following the decisions made on the previous concept, the design was examined against the consumer requirements ordinally outlined in the project and environmental constraints before being developed through sketching and CAD modelling.
31. 32.
One of the main problem areas with the previous design was the imposing large size of the product. It was also concluded that the low pressure collection bin was too large for the target market and the theorised acceptable amount of heavy dust/debris that would need to be collected. This element was condensed and designed to be more compact, allowing the product to be made shorter and have a lower centre of gravity to make it more stable.
The redesign also allowed a larger cable retractable spool to be incorporated into the design as it was further compacted and condensed into a functional but fully considered product.
33. 34.
6.0 Design solution.
6.1 Description and justification.
The Dremel Airwave 800 is a fume extractor that also doubles up in function as a vacuum cleaner. These versatile functions are achieved with a low and high pressure separation element within the product to deal with the different types of DIY/hobbyist dust and debris.
Designed as a way of dealing with the health risks from fine and sub-micron particles in the air, the high pressure separation elements are able to remove these particles from the airflow prior to active carbon filtration to neutralise any gasses in the air. By removing these particles prior to filtration the active carbon granules in the filter will have over double the life span of a similarly priced fume extractor as the pores in the filter cannot be clogged.
The Dremel Airwave 800 has a compact and condensed design to allow for a smaller overall product suitable for a DIY/hobbyist’s working environment. The product has also been functionally developed with a range of features and at its highest settings can rival any unit for a similar price point currently on the market in terms of air watt’s of movement.
35. 36.
6.2 Visual aesthetics.
The Dremel Airwave 800 has been specifically developed to fit in with the current range of Dremel products. Its styling, colour and material choices have been selected to match in and be sympathetic to the existing house styles.
With the extractor being a new product branch for Dremel there are some styling differences required by the specific product such as the large clear and smoked polycarbonate mouldings that make up the containment bins. The function driven style of Dremel can also be seen in the way that ‘omni wheels’ have been redeveloped and utilised to add useful features and some needed storage into the product; although these are unique to this product within the brand they are within keeping to the brands design intent.
37. 38.
6.3 Airflow and separation methods.
The main suction in the Dremel Airwave 800 is created through a compound turbine stack which also acts as a part of the high pressure separation element. This has been developed through physical prototyping to achieve the greatest suction at relatively low speeds to increase the efficiency of the product. The turbine is made up of a number of different layers that allow the air to be span out at high force in ranging pressures to aid the separation process.
39. 40.
6. 4 Variable suction.
To improve the functionality of the extractor, the Dremel Airwave 800 features fully variable suction. The extraction can be controlled manually by a variable switch next to the main on/off button on the top on the product.
This feature is particularly useful to the DIY/Hobbyist market as when working on smaller and delicate items with an extraction tool near the work, the level of suction needs to be reduced so that the work is not effected and no material is mistakenly vacuumed into the product.
Some tasks may also require the product to be used for longer periods of time and the suction level can be altered to both what is appropriate to the task and an acceptable audible level.
Finally, the product can be used in its full power mode by moving the slider from L (low) to H (high) for maximum suction when cleaning up.
6.5 Auto start line out feature.
The Dremel Airwave 800 is equipped with 2 electrical sockets that can be used to run power tools. These electrical outlets are usually covered by injection moulded wing covers to protect the socket, and can be accessed by raising up the cover.
The cover also has a cam on the rear that interfaces with an isolation switch that only puts power to the socket when the button is depressed by the cam.
The circuit is designed to detect loading on the outlet to allow the extractor to start up when power is being drawn to run a power tool. An LED indicator on the top of the product illuminates to indicate when the outlet is active.
This feature is particularly useful to DIY/hobbyists as it allows an extraction tool to be added onto the extractor and only the power tool needs to be operated.
7 LED lights illuminate a plastic indicator strip as a secondary indicator to the suction level of the product.
41. 42.
6.6 Removing and emptying the bins.
The Dremel Airwave 800 features 2 separate containment bins:The low pressure containment bin mainly collects chips, general debris and dense/medium dust. The bin is held in place against a rubberised gasket by spring loaded ball Barings and can be removed by simply pulling forward. Once the bin is removed the rear opener can be unclipped and the contents can simply be deposited into a waist bin.
43. 44.
The high pressure containment bin collects fine and sub-micron particles. This bin is also held in place by spring loaded ball bearings and can be pulled away from the main product with relative ease. With these being significantly more harmful if becoming airborne it is recommended to dampen the contents and use the provided tool to clean out the bin. If required the bin can be rinsed out but must be allowed time to dry before being replaced onto the product.
6.7 Omni wheels.
Omni wheels have been used for the Dremel airwave 800 to allow the product to be easily moved in any direction. As the product will most likely be used on a small worktop it needs to be able to be easily moved about (especially with the provided intake tool attached) to allow the user to get the extraction exactly where they need it.
The Omni wheels work by allowing the small Omni’s (in blue) to rotate freely on their mounts to allow for lateral movement whilst linier movement is achieved by the entire wheel turning. The wheels also allow for diagonal movement for the product as all parts rotate in unison upon contact with the work surface.
Omni wheels are usually an expensive product, however they have been redesigned to be made from 2 injection moulded parts. The main wheel rotates on pinions around and internal stainless steel tube to allow for smooth running and a hollow wheel.
6.8 Storage.
The Dremel Airwave 800 features some internalised storage for the key required components for operation and maintenance, and also to allow the product to become more compact. With the intelligently designed Omni wheels running on a stainless steel tube, the cavity inside is used for storage.
The rear wheel houses the mains power plug when the extractor is not in use for protection and easy storage. (Image bottom left.)
The front left wheel storage area houses the Dremel universal inlet connector which can be clicked onto the low pressure containment bin inlet and allows any tool or hose to be attached. This attachment will be commonly needed when using non Dremel tools and hoses so is provided as standard with the product. (Image bottom centre.)
The front right wheel storage area houses the felt and bristle Dremel cleaning tool required for the proper maintenance and cleaning of the high pressure containment bin. This tool is clipped into place and concealed in the storage area for convenient access and use. (Image bottom left.)
45. 46.
6.9 Retractable cable.
A 3 metre retractable cable has been designed into the main body of the product for convenient use. The rear storage area that houses the plug when the product is not in use, has pin rolers to feed the cable on and off the spool smoothly.The product also features a spring loaded retractor paddle with friction plates to allow the cable to be manually retracted when required.
6.10 changing the active carbon granules.
The filter in the Dremel Airwave 800 has been specifically developed to allow the end user to replace the active carbon granules in the filter themselves. This option has been designed into the product to allow for a small filter that retains its large surface area and can be incorporated into the outer form of the product. Replacing only the granules also reduces the cost to the consumer and minimises the environmental impact as no full filters are replaced or disposed of.
47. 48.
6.11 Default intake tool.
The Dremel Airwave 800 will come with its own unique intake tool when purchased. The tool is made to fit onto the Dremel universal inlet attachment (usually stored in the left wheel) and has been functionally designed for fume and airborne dust extraction.
The tool is able to rotate about its mount and is also designed with a tight pivoting connector to allow the intake tool to be moved to a suitable position and it remain where it is placed. The tool also featured a sculpted backing to the intake pad to allow for improved airflow to each intake vent.
The intake vents on the front of the intake pad gradually increase in size and shape as they radiate out further from the intake nozzle, allowing for a regulated and constant amount of suction across the surface of the tool.
49. 50.
6.12 Materials, manufacturing and main components.
1. Base moulding. 2. Mains 3 metre cable spool with spring loaded live barings. 3. Rear wheel internal moulding.4 Pin rollers for mains cable5. Stainless steel running surface for omni wheel needle bearings. 6. Stainless steel lower containment bin back runners. 7. Dome headed screw. 8. Spring loaded ball baring retainer clips. 9. front retainer clip moulding. 10. Rear and defuse cavity moulding. 11. Upper case moulding. 12. Vent covers and handle base panel moulding. 13. Energy efficient motor. 14. Circuit boards. 15. Main power button.16. Variable power slider. 17. Turbine stack. 18. Lower vent casing for motor to product air-flow. 19. Anti-flow bearing cover.20. Main motor bearing. 21. Front motor retaining mount. 22. Cable retractor paddle assembly. 23. Rear product casing. 24. Separation element rear casing and venting element. 25. Right casing panel. (With outlet socket backing included.) 26. Left plug cover. 26. Left plug cover. 27. Stainless steel lower containment bin front runners.28. Upper turbine front casing. 29. Flat headed screw.30. Main separation cone moulding.
31. High pressure containment bin gasket. 32. Filter gasket. 33. Active carbon filter assembly.34. High pressure containment bin. 35. Low pressure collection bin assembly. 36. Universal outlet connector. (Inside of the left wheel storage.) 37. Front wheel internal mouldings. 38. Omni wheel (right and rear wheels.) 39. Omni wheel (left wheels.) 40. Mains power plug. 41. Wheel storage covers upper mounts. 42. Rear wheel storage cover with cable outlet. 45. Right plug cover. 46. Dremel product cleaning brush. 47. Front wheel storage cover.
The majority of the components in the product are made from injection moulded ABS as it can create a range of durable and long lasting parts.
Stainless steel 1mm sheet has been used on some components to build up a durable and long lasting running surface for parts.
Elastomer rubberised mouldings have been used to form a range of gaskets and seals within the product as it is a durable and long lasting material.
The clear plastic elements on the product are produced in polycarbonate as it is a robust material that has some flex and can stand up to repeated knocks and bangs during its lifespan.
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Dermal Airwave 800 exploded diagram. (main parts)
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6.13 General arrangement.
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6.14 SWOT analysis
Strengths.
One of the main strengths of the Dremel Airwave 800 over competitor products currently on the market is that it combines two very similar products that are ideally needed in the DIY/hobbyist environment. By combining a fume extractor and a vacuum cleaner the consumer now only has to purchase one product but gets the benefit from both, along with unique benefits only found on high end workshop vacuum cleaners such as the ‘auto start line out feature’. The aesthetics of the product also break away from pure ‘form follows function’ design whilst maintaining the Dremel design house style to produce a fresh and desirable product.
Weaknesses.
One of the weaknesses of the Dremel Airwave 800 comes as part of the developments in design with the necessity to miniaturise the product to suit its intended environment; the low pressure main containment bin is limited in its holding capacity so would not be ideal for larger workshops or tasks that produce a larger volume of debris. There is also a weakness in that the product is designed to be a sealed unit and with its numerous injection moulded casing parts would be difficult for an end user to dismantle if needed.
Currently the active carbon filter element in the product has been designed so that it can either be completely replaced (including the injection moulded skeletal form) or just the active carbon granules can be replaced. If these granules are replaced improperly it may cause some harmful gasses to escape. Instruction on proper procedure would be provided in the product manual however this may not be accurately followed by the end user.
Another weakness may be that the product cannot store the extraction tools or hoses onto its own body and these need to be stored elsewhere.
Opportunities.
Although the design of the Dremel Airwave 800 is limited to just the core product at present, it would be possible for Dremel to start and produce a related product range of tools and attachments specifically designed to work in conjunction with the product in the DIY/hobbyist environment. This would increase the Dremel product portfolio and would also allow for a greater profit from these new sales.
In addition to this, the Dremel Airwave 800 has also been designed to link up to and accommodate a number of pre-existing extraction and vacuum cleaning products and tools so future new product developments for the company could be ran in conjunction with a pre-existing manufacturers to reduce costs.
There is an opportunity to sell more units based off the current climate for health awareness and people being more knowledgeable about the risks associated with the type of fine particles and fumes that the Dremel Airwave 800 effectively deals with.
Threats.
The main current threats to the product come from the facts that the product still requires further and more precise technical development to validate any claims and to meet up with any standing legislations. If unproven Dyson (one of the main competitors for the product) are well known for testing their competitor’s products and claims.
Although there are currently no similar competitor products there is a considerable threat from other manufacturers that may have been working on a similar product due for realise; or from competitors that may copy the basic design format and function for a reduced price and undercut the market. Strong patents will be needed on all elements of the design and some of its variations to limit this.
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7.0 Conclusion.
The Dremel Airwave 800 fume extractor/vacuum cleaner is a compact and versatile product well suited to the DIY/hobbyist market that fits well into the current Dremel product range. The design has a number of desirable features such as its separate collection bins, relatively silent extraction and ‘auto start line out feature’. The product has been designed with the end user in mind and its compact design would easily sit on any workstation desk to provide extraction directly where it is needed. The stylish design would not look out of place in a craft room or small workshop and caters for a wide range of tasks with the correct tool in place.
If the product were to be taken any further it would be required to spend more time fine tuning the design of the turbine and airflow channels to increase the efficiency of the separation. There is also the requirement of work on a number of extraction tools however this does give the opportunity for Dremel to develop their own range of task specific tools.
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8.0 Bibliography.
http://www.purex.co.uk/ http://www.dremeleurope.com/gb/en/ hptt://www.eco-generation.org/ambassador.ReportView.jsp?viewID=7706 http://dremelnewsroom.com/dremelenewsletters/February2012/index.html#4 http://www.viking-direct.co.uk/a/pb/Numatic-George-Four-in-one-vacuum-cleaner-1200-watts/pr=Q25&id=GVE370/http://www.dyson.co.ukhttp://www.wad.co.uk/?gclid=CjwKEAjw3_ypBRCwoKqKw5P9wgsSJAAbi2K9Fk0t-TuXLJ58GzLaHrN53k8trSJUVcxguZvep-kw-CRoC2eHw_wcBhttp://www.airbench.com/?gclid=CjwKEAjw3_ypBRCwoKqKw5P9wgsSJAAbi2K9HnxhagFgfFGDOq-uH85LoX1P-slBQp003HVz678GEKhoCzmXw_wcBhttp://www.flextraction.co.uk/http://www.fumecupboards-direct.com/?gclid=CjwKEAjw3_ypBRCwoKqKw5P9wgsSJAAbi2K9U9kctdh8aMs9LksQ87aEJkygC-Z6Imj76REB3yEPHWhoCzivw_wcBhttp://www.aessolutions.co.uk/blog/http://www.aessolutions.co.uk/product-areas/dust-fume-extraction/weld-fume/http://www.autoextract.co.uk/p/Paint_Solvent_fume_Extraction.php?type=6
9.0 List of illustrations. http://www.dremeleurope.com/gb/en/ page 4 http://www.dremeleurope.com/specials/book-of-inspiration/gb/en/ page 5 https://brittajewelry.wordpress.com/category/uncategorized/ page 6 https://davidneat.wordpress.com/tag/model-making-jobs/ page 6 http://dremelnewsroom.com/dremelenewsletters/February2012/index.html#4 page 6http://www.purex.co.uk/fume-extraction/examples-of-hazardous-fumes/ page 7 http://www.desso-airmaster.com/en/home/business/desso-airmas-terr/reducing-fine-dust-in-the-breathing-zone/ page 8http://www.viking-direct.co.uk/a/pb/Numatic-George-Four-in-one-vacuum-cleaner-1200-watts/pr=Q25&id=GVE370/ page 11 https://www.machinemart.co.uk/shop/product/details/bosch-gas-35-m-afc-m-class-35-litre-profession-2 page 11 http://uk.farnell.com/weller/wsa350eu/bench-top-smoke-absorber-20w-230v/dp/2426414?ost=2426414&mckv=xvxVx8E9%7-Cpcrid%7C60421057509%7Cplid%7C&CMP=KNC-GUK-FUK-GEN-LISTINGS-SHOPPING-WELLER&CAGPSPN=pla&gclid=CjwKEAjw3_ypBRCwoKqKw5P9wgsSJAAbi2K9IAzOZM3XsFVGLa5F52trot-e0Mn8-zZ53zv93AxdSxoC15nw_wcB&CAWELAID=120173390000537734&gross_price=true page 11 http://www.ebay.co.uk/itm/like/360959907851?limghlpsr=true&hlpv=2&ops=true&viphx=1&hlpht=true&lpid=108&chn=ps&device=c&rlsatarget=&adtype=pla&crdt=0&ff3=1&ff11=ICEP3.0.0-L&ff12=67&ff13=80&ff14=108 page 11 http://www.dremeleurope.com/gb/en/ page 38 http://www.google.co.uk/url?sa=i&rct=j&q&esrc=s&source=images&cd&cad=rja&uact=8&ved=0CAcQjRw&url=http%3A%2F%2Fpixgood.com%2Ftrash-can-icon.html&ei=RHk-Vfb-JtbxavGCgMgI&bvm=bv.91665533%2Cd.d2s&psig=AFQjCNHFTUwGrN3MNG1YDwRRtQvndb0kKg&ust=1430244031690247 page 43http://www.google.co.uk/url?sa=i&rct=j&q&esrc=s&source=images&cd&cad=rja&uact=8&ved=0CAcQjRw&url=http%3A%2F%2Fpixgood.com%2Ftrash-can-icon.html&ei=RHk-Vfb-JtbxavGCgMgI&bvm=bv.91665533%2Cd.d2s&psig=AFQjCNHFTUwGrN3MNG1YDwRRtQvndb0kKg&ust=1430244031690247 page 44 http://www.thinkstockphotos.ca/image/stock-illustration-water-icon-set/161760021 page 44 http://www.google.co.uk/url?sa=i&rct=j&q&esrc=s&source=images&cd&cad=rja&uact=8&ved=0CAcQjRw&url=http%3A%2F%2Fpixgood.com%2Ftrash-can-icon.html&ei=RHk-Vfb-JtbxavGCgMgI&bvm=bv.91665533%2Cd.d2s&psig=AFQjCNHFTUwGrN3MNG1YDwRRtQvndb0kKg&ust=1430244031690247 page 48.
All renders, photographs and sketch work images shown in this report have been produced by the student during the duration of this project. These images are not listed here and are displayed on the pages that they relate too.
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10.0 Appendixes.
Fume Extractor Concept Project.
Product and Project Briefs.
Current market trends show that there is a certain threshold to where a consumer will undertake tasks and ignore the needs for fume extraction, to when fumes become enough of a problem that the consumer will consider purchasing a solution. This threshold is mainly effected by how often a person undertakes a task that generates fumes and how toxic they are; but there are also correlations with the price point and desirability of fume extractors that may affect their decision to buy. Consumers undertaking fume producing tasks on a regular basis will have most likely purchased some form of fume extraction, but there are a number of problems and continual costs through these product’s life spans which may cause consumers to be continuing to look for a better option.
Future market trends are being influenced by the general public’s growing awareness to the damage that fumes are doing to their health, as well as people’s desire to be healthy, green and more energy efficient. This will lead to more people that currently undertake fume producing tasks, as well as a large percentage of the younger population starting with these tasks to consider buying a fume extractor. Their decision on witch product to purchase will most likely be function driven but aesthetics and usability will also play growing roles. The product would there for need to offer more than just basic function, with the possibility of further consequential functions, and have a desirable look and feel to the product.
Project Aims.
Essential/Mandatory Features.
The fume extractor will need to be of a small manageable size so that it can be marketed at both the higher production end of the ‘DIY hobbyist’ market and into the semi to full professional market places. The product will need to be of a reasonable price point, but will need to give a very high performance and high amount of air flow per second to compete in the market. The product would also need to pass related legal requirements and clarification pro-vided as for what type and volume of fumes can be dealt with.
Highly Desirable Features
The Fume extractor will need to be designed in ways that will suite the modern market for low power consumption goods that are energy efficient. The product itself will need to be value engineered to use the minimum materials whilst keeping its robustness and ability to function at a high level. Con-sideration also needs to be placed into designing the product to require minimum maintenance but have the longest possible life span. It may also be pos-sible to design the product with sub-assemblies so that parts may be replaced or even upgraded if they ware over time.
Desirable/Non-essential Features.
For the fume extractor to sell predominantly over its competitor it will need to have either a single main key feature, or a number of smaller revelations that give this product a higher functionality than others on the market. The added features will be tested and developed during the design process, but may include:
• The capability to handle soot and sub-micron particles in fumes.
• Anti-clogging design.
• Active carbon or ceramic filtering systems, developed to last as long as possible.
• Light weight and compact design, with all the power of a larger industrial unit.
• Possible ability to pick up dust and debris in the workplace such as a vacuum cleaner would.
Aesthetics.
The fume extractor’s competitors on the current market are currently all ‘grey metal box’ styled units of varying sizes with black ducting. This is one of many products in the workshop that has not seen much innovation or change in a number of years, so there is much scope for changing the products aesthetics. Depending upon the extra added features, basic design and movability factor, the aesthetics will be developed to suite the product and be desirable to the modernising market.
Price.
The price point of the product should be kept to a minimum where possible if just a basic function is developed. If one or more of the desirable additional functions can be added in (which would also mean inevitably more materials and complexity in the design) then the product would be able to sell for a slightly higher price point. The price would need to be competitive with the products currently available on the market, and if it is branded by a larger company will also need to carry the weight of such a brand.
Expected Deliverables.
• Conceptual proof of concept model. (Fully working but not necessarily to the same scale or layout as the finalised design.)
• Presentation model. (full colour and precisely produced. This may be just a cosmetic model.)
• Full technical report.
• Basic outline for a priced up production and marketing strategy.
• Presentation boards and graphically based product sales materials.
• Verbal product presentation backed up with the use of a power point, models and other such supporting materials.
Resources required.
To complete this project a range of design and engineering based skills will be required. As the sole lead designer on this project I will be responsible for these tasks from the first to last stage in the design process.
To aid this process, additional skills may need to be learnt in terms of design understanding specific to this project; related technical skills and the ability to fully test prototypes in different manners for analysis and development purposes.
The majority of all of the tasks required, wherever possible, will be performed ‘in house’ within the main design building. If it is required for further testing other resources may be requested from other departments within the university; whereby prototypes and technical data may be taken to be discussed or tested by experts in their field.
Design management skills will be extensively required to effectively time manage the project and keep it on track. In addition to this, management skills will be required to co-ordinate and organise times to run prototype testing, as well as organise any specific materials and processing that may be required during building phases.
Cost.
The cost of the design project will be kept to a minimum by the full utilisation of all of the in house design resources, along with the materials bill already pre as-signed to this project.
Project Duration.
The project will be strictly time controlled to ensure that pre-set goals are being achieved on time to ultimately meet the delivery dates for each main element of the project. Please refer to the ‘time and task allocation planner’ document for further clarified details on the project.
Project element over-runs have been calculated into the planner to allow some ‘Leigh-way time’ to account for any tasks that run over time. This has added small time buffers in-between the main project elements to reasonably ensure that the end deadline can be met. These buffers are also in place so that if a resource becomes unavailable or brakes down there is time designed in to allow for the securing of alternative resources.
Project Limitations.
Due to the short time scale of this project, there may only be time to prove out the core functionality of the product. There may be areas of the product remain-ing not fully function tested, and there still may be some further refinement required to increase the function and efficiency of the product. It can not be assumed or taken for granted that production ready designs will be produced. Further refinement, modifications and value engineering may be required in order to meet legal requirements, technical constraints and desired cost specifications.
Project Financial and Resources Risks.
Some research has already been carried out witch indicated a gap in the market for the proposed product, and there is little to no evidence that other companies and design houses may be undertaking the development of a similar product. This is as of the product being a ‘background product’ that is not commonly no-ticed, or has inadequate ways to remove the use for such a product.
There is some risk related to the proposed project as of the time and resources that will be committed to its undertaking, however with the current dedicated team it should be possible to create a functionally and financially viable product to take to market.
Signed:
_____________________________________ Date: __/__/____
(Lead Designer)
Signed:
_____________________________________ Date: __/__/____
(Teesside University Official, Middlesbrough)
