Mech 202 Project 1 Report

Group Number 35

Group Members Email Addresses

Section Pages where found

a. Cover sheet 1 b. Photo and superimposed CREO model 2 c. Project pland. Exploded assembly drawing(s)e. Bill of materialsf. Detailed description of how device worksg. 2D engineering drawingsh. Description of researchi. Sketch, description, and analysis of improvementj. Teamwork analysis

Supplemental Information Where located

Sten LarsonJustin WeinmeisterTroy JohnsonJace Horak

[email protected]@[email protected]@gmail.com

ManualDesign Structure MatrixWebsite Lists

3-1011-12

13-1516-7225-7273-7677-9192-105

106-107108109

Project 1 Mech 202 Group 35

1


2

As can be seen from Gantt chart snapshots, our group started the project ahead of schedule, but quickly fell behind. Our group started ahead of schedule by buying the vacuum and disassembling it before planned. After this initial disassembly, we meet Bob Thilmont on February 3 to discuss or progress and were still ahead of schedule at that point. Following this meeting we had only planned team check-ups following lectures until the final weekend. This structure kept the group together, but it allowed us to slip behind schedule as accountability was not high. Progress seemed to be good in the PTC Creo models; however, the parts were not being checked, and they were incomplete in some aspects. This caused delays. Further delays were caused by late starts in the product decomposition and product improvement sections.

The Gantt chart was created in Google spreadsheets because the online file could be accessed by all team members from any device to check our status at any time. This was deemed better than Microsoft projects software as that would require team members to either be on campus or login via virtual lab to access the chart. Improvements to the plan could have been made by assigning check dates. These dates would require a person’s buddy, as defined in our buddy system, to check their buddy’s work and make sure they are not only on schedule but that their work meet all requirements and met team standards. The addition of these check dates as milestones will be incorporated into project 2 for Mech 202.

The final weekend of the project was complicated by the absence of two of the team members from Fort Collins as both were representing CSU out-of-state. During this weekend almost 60 hours of combined work was done. This was a beyond reasonable workload that resulted in disappointment for the team. The project was still completed on schedule by the team pulling together, though.

The first snapshot is the initial project plan with updated meeting dates. The initial plan had our first team meeting on Sunday 2/1/15 instead of Thursday 1/29/15. The final meeting was also originally scheduled for Sunday 3/1/15, but it was moved to Monday 3/2/15. Both of these moves were deemed non-consequential as they were moved due to schedule conflicts with school sponsored activities. Most tasks were designed to be done separately and quickly; however, some tasks had to be done over a long period of time due their nature. These tasks included the recommended improvement, non-unique product descriptions, bill of materials, and the Gantt chart.

The second snapshot is from Sunday 2/1/15. At this point in the project, the team was ahead of schedule for the bill of materials and behind on none. This made the team optimistic about the difficulty of the project and likely lead to some of the delays seen later on in the project.

The third snapshot is from Sunday 2/8/15. At this point non-unique product descriptions, device operation description, and recommended improvements were behind schedule. The critical task of the PTC Creo models was on schedule, though it was not yet know at this point that some models were actually deficient for our purposes.


3

The fourth snapshot is from Sunday 2/15/15. The bill of materials, PTC Creo models, non-unique product descriptions, device operation description, and recommended improvement tasks were behind schedule. The PTC Creo delay could interfere with the critical task finishing on time; however, the delay was minimal and did not worry our group at this point.

The fifth snapshot is from Sunday 2/22/15. At this point the PTC Creo drawings, non-unique product descriptions, complete PTC Creo model, device operation description, and recommended improvements were behind schedule. At this point the our group realized the seriousness of our delays, but due to scheduling, very little work was going to occur until the following weekend.

The sixth and final snapshot is from Monday 3/2/15. At this point the only task behind schedule was reviewing all parts. The only remaining work scheduled was in reviewing the final product and turning it in. This task had a known time and was listed for the next day in order to put the Gantt charts in the project report for final assembly. The team could see where they had gone wrong and realized the above improvements at this time.

A design structure matrix can be found in Appendix B to further clarify how dependencies were found.


4

S M T W R F S S M T W R F S S M T W R F S S M T W R F S S M T W R F S S M T W

25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3 4

1 Purchase Vacuum 1/25/2015 1/28/2015 JH 0 1 0

2 Pre-disassembly research 1/29/2015 1/31/2015 1 JH 0 6 0

3 Disassembly 2/1/2015 2/1/2015 1,2 TJ, JH 0 4 0 --

4 Bill of Materials 2/1/2015 2/21/2015 3 JW 0 12 0

5 Creo model-20 critical 2/2/2015 2/14/2015 3 TJ, JH 0 60 0

6 Creo Drawings 2/15/2015 2/27/2015 5 TJ 0 10 0

7 Non-unique product description 2/1/2015 2/27/2015 3,4 JW 0 10 0

8 Complete Creo Model 2/15/2015 2/21/2015 5 SL 0 20 0

9 Creo Exploded View 2/22/2015 2/27/2015 8 TJ 0 5 0

10 Reassembly 2/28/2015 3/1/2015 9 JH 0 2 0

11 Cover Page 2/22/2015 2/27/2015 SL 0 1 0

12 Cover Photo 3/1/2015 3/1/2015 9 JH 0 2 0 ---

13 Device Operation Description 2/1/2015 2/14/2015 3,4,7 JW 0 6 0

14 Recommended Improvements 2/15/2015 2/24/2015 2,13 SL 0 15 0

15 Teamwork Review 2/25/2015 2/27/2015 JW 0 4 0

16 Review all Parts 2/28/2015 3/1/2015 12,14 SL 0 8 0

17 Gnatt Chart 1/26/2015 2/28/2015 JW 0 10 0

18 Final Product Assembly 3/2/2015 3/4/2015 12,14,15,16,17 SL 0 6 0

19 Team meetings Team 0

20 Team Check Ups 1:20 PM Team 2 0

21 Project Due Date Team

Total Hours 0.00% 184 0

Units Inch Planned Time

Software Google Sheets Actual Time

Buddy Troy<->Jace Critical Path ----------

System Sten<->Justin Milestones

Number Task Start Finish Dependencies Resources % CompleteEstimated

HoursActualHours

January Feburary March

--------------------

-------------

-----------------------------------------------------------------------

----------------------------------

-------------

------

Outside Chem A101

JH = Jace Horak

TJ = Troy Johnson

SL = Sten Larson

JW = Justin Weinmeister


5


25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3 4






6 Creo Drawings 2/15/2015 2/27/2015 5 TJ 0 10 0




10 Reassembly 2/28/2015 3/1/2015 9 JH 0 2 0

11 Cover Page 2/22/2015 2/27/2015 SL 0 1 0

12 Cover Photo 3/1/2015 3/1/2015 9 JH 0 2 0 ---





17 Gnatt Chart 1/26/2015 2/28/2015 JW 40 10 4


19 Team meetings Team 2.5

20 Team Check Ups 1:20 PM Team 2 0.3


Total Hours 10.27% 184 21.6






HoursActualHours


--------------------

-------------

-----------------------------------------------------------------------

----------------------------------

-------------

------

Outside Chem A101

JH = Jace Horak

TJ = Troy Johnson

SL = Sten Larson



6


25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3 4






6 Creo Drawings 2/15/2015 2/27/2015 5 TJ 0 10 0




10 Reassembly 2/28/2015 3/1/2015 9 JH 0 2 0

11 Cover Page 2/22/2015 2/27/2015 SL 0 1 0

12 Cover Photo 3/1/2015 3/1/2015 9 JH 0 2 0 ---





17 Gnatt Chart 1/26/2015 2/28/2015 JW 40 10 4





Total Hours 15.82% 184 31.6






HoursActualHours


--------------------

-------------

-----------------------------------------------------------------------

----------------------------------

-------------

------

Outside Chem A101

JH = Jace Horak

TJ = Troy Johnson

SL = Sten Larson



7


25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3 4






6 Creo Drawings 2/15/2015 2/27/2015 5 TJ 0 10 0




10 Reassembly 2/28/2015 3/1/2015 9 JH 0 2 0

11 Cover Page 2/22/2015 2/27/2015 SL 0 1 0

12 Cover Photo 3/1/2015 3/1/2015 9 JH 0 2 0 ---





17 Gnatt Chart 1/26/2015 2/28/2015 JW 50 10 5





Total Hours 28.78% 184 55.6






HoursActualHours


--------------------

-------------

-----------------------------------------------------------------------

----------------------------------

-------------

------

Outside Chem A101

JH = Jace Horak

TJ = Troy Johnson

SL = Sten Larson



8


25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3 4






6 Creo Drawings 2/15/2015 2/27/2015 5 TJ 20 10 2




10 Reassembly 2/28/2015 3/1/2015 9 JH 0 2 0

11 Cover Page 2/22/2015 2/27/2015 SL 0 1 0

12 Cover Photo 3/1/2015 3/1/2015 9 JH 0 2 0 ---





17 Gnatt Chart 1/26/2015 2/28/2015 JW 60 10 6





Total Hours 54.89% 184 82.6






HoursActualHours


--------------------

-------------

-----------------------------------------------------------------------

----------------------------------

-------------

------

Outside Chem A101

JH = Jace Horak

TJ = Troy Johnson

SL = Sten Larson



9


25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3 4






6 Creo Drawings 2/15/2015 2/27/2015 5 TJ 100 10 4




10 Reassembly 2/28/2015 3/1/2015 9 JH 100 2 1

11 Cover Page 2/22/2015 2/27/2015 SL 100 1 1

12 Cover Photo 3/1/2015 3/1/2015 9 JH 100 2 2 ---





17 Gnatt Chart 1/26/2015 2/28/2015 JW 100 10 7





Total Hours 100.00% 184 146






HoursActualHours


--------------------

-------------

-----------------------------------------------------------------------

----------------------------------

-------------

------

Outside Chem A101

JH = Jace Horak

TJ = Troy Johnson

SL = Sten Larson



10

Dirt Devil Group 35T Johnson

2.4

2.7

1.7

1.4

1.2

1.6

1.3

1.1MotorSub-Assembly

2.3

3.3

2.53.5/3.7

2.1

4.6

2.8

2.9

1.12

2.1


11

Exploded Assembly:

Creo Models found in Zip folder under folder name "Creo"

Motor Assembly Group 35J. Horak

3.1

3.2

3.15

3.10

3.13 3.12

3.1.4


12

Motor Sub-Assembly:

Part Number Part Name Manufacturing Proces Quantity Description Weight Time Units

Nose Assembly

1.1 Filter 1 Cotton/LDPE 22.9 grams

1.1.1 Weaving 1 30 seconds

1.1.2 Injection Molding 1 10 seconds

1.2 Crevice Tool 1 PP 19.1 grams


1.3 Cup 1 ABS 111.5 grams


1.3.2 Assembly 1 30 seconds

1.4 Cup Lid 1 ABS 62.8 grams


1.5 1-1/8" Blind Rivet 2 Steel 1 grams

1.5.1 Closed Die Forging 2 0.1 seconds

1.5.2 Riveting 2 0.5 seconds

1.6 Left Release Tab 1 ABS 4 grams



1.7 Right Release Tab 1 ABS 4 grams



1.8 Tab Springs 2 Spring Steel (0.5"x0.5") 1 grams

1.8.1 Cold Winding 2 5 seconds

1.9 Cup Lid Springs 2 Spring Steel (1"x0.5") 1 grams


1.10 Cup Lid Bottom Gasket 1 Silicone 0.5 grams


1.10.2 Gluing 1 seconds

1.11 10x24 5/16" #2 Philips Pan Head 3 Steel 1 grams

1.11.1 Thread Rolling 3 0.1 seconds

1.12 Crevice Tool Housing 1 ABS-TPE 42.8 grams


1.12.2 Over-molding 1 20 seconds


1.13 Cup Lid Top Gasket 1 Polyurethane (2"x2") 0.5 grams

1.13.1 Molding 1 30 seconds

1.13.2 Gluing 1 1 seconds

Rear Housing





2.3 Left Housing (Screws) 1 ABS 143.4 grams



2.4 Right Housing 1 ABS 148.5 grams


2.5 Power Switch 1 ABS 4.5 grams


2.6 Filter Release Spring 1 Spring Steel (0.75"x0.25") 1 grams


13


2.7 Filter Release Tab Top 1 ABS 2 grams



2.8 Filter Release Tab Bottom 1 ABS 5 grams




Motor Assembly

3.1 Batteries 8 Wintonic Ni-Cd SC1300mAh 1.2V 140 39 grams

3.1.1 Cell Construction 8 30 seconds

3.1.2 Packaging 8 5 seconds

3.1.3 Printing 8 1 seconds


3.1.5 Wiring 8 30 seconds

3.2 Motor 1 SRC-540S-7226F 162.4 grams

3.2.1 Casting 1 120 seconds

3.2.2 Winding 1 60 seconds

3.2.3 Stamping 1 10 seconds



3.3 Charging Port 1 HDPE (5V DC) 1 grams


3.3.2 Soldering 1 10 seconds

3.4 Fuse 1 Glass (250V, 15A) 0.7 grams

3.4.1 Glass Blowing 1 5 seconds

3.4.2 Capping 1 1 seconds

3.4.3 Soldering 1 5 seconds

3.5 Circuit Board 1 Pertinax and Copper 8 grams

3.5.1 Layering 1 5 seconds

3.5.2 Silk Screen Printing 1 0.5 seconds


3.6 Led 1 HDPE (Red) 0.3 grams


3.7 Circuit Switch 1 Steel 5 grams

3.7.1 Stamping 1 5 seconds


3.8 18 AWG Wire 4 Copper 1.5 grams

3.8.1 Drawing 4 1 seconds

3.9 24 AWG Wire 3 Copper 1.5 grams

3.9.1 Drawing 3 1 seconds

3.10 Rear Impeller Housing 1 ABS 18 grams


3.11 10x24 3/8" #2 Philips Flat Head 3 Steel 1 grams


3.12 Front Impeller Housing 1 ABS 15.8 grams


3.13 Impellar 1 ABS 20 grams





3.15 Battery Housing 1 ABS 25.3 grams


14



Packaging

4.1 Cardboard 1 Cardboard (18"x6"x6") 150.5 grams

4.1.1 Corrugating 1 5 seconds


4.1.3 Packaging 1 30 seconds

4.2 Top Paperboard 1 Paperboard (6"x6"x4") 57.3 grams


4.3 1 Paperboard (6"x6"x4") 59.7 grams


4.4 Product Registration Sheet 1 Paper (4"x12") 5.6 grams

4.4.1 Offset Lithography 1 1 seconds

4.5 Manual 1 Paper (8.5"x11") 15.1 grams

4.5.1 Offset Lithography 1 1 seconds

4.6 Charger 1 5V, 350mA 64.2 grams

4.6.1 Injection Molding 1 HDPE 10 seconds

4.6.2 Casting 1 Iron 120 seconds

4.6.3 Winding 1 Copper 60 seconds

4.6.4 Wiring 1 Copper 30 seconds


Totals 1523.2 grams

1236.7 seconds

Bottom paperboard (Handle Indent)

All dimensions are standard


15

Vacuuming:

Overview:

A. Shows the overall path of air through the vacuum. It first enters the crevice tool, then proceeds through the dirt cup and filter before entering the impeller through the grate. At the impeller, the air is forced to the outside of the impeller housing, to the backside, and then back again to the center before being directed along the motor and batteries to the exits in the rear housing.

B. Shows the dirt path. It flows with the air into the dirt cup before being stopped by the filter and deposited.

The vacuum operates using pressure differentials. There is no such thing as “suction”, the effect seen is when air rushes to fill a partial vacuum. This rushing appears to suck air, and any nearby dirt, into the vacuum opening. This partial vacuum is created by forcing air through an impeller. The impeller accelerates air from its eye to the outside edges. The air is accelerated because the fins of the impeller can “grab” some air and move it along multiple vanes that are shaped to accelerate the air mass. The high revolutions per minute of the impeller means that though each turn moves only a small air mass, the cumulative effect is large. The velocity increase of the air creates the low pressure area at the impeller eye and a higher pressure area at the outside edges. The incoming air picks up dirt and other objects as it travels to and through the vacuum, and it is deposited inside the vacuum when the air passes through a filter smaller than the particulate size. The impeller is turned by an electric motor (explained in product decomposition, parts section). Additional parts needed to operate the vacuum are batteries to supply the electric energy, a charging circuit, and an operating circuit. Both of these circuits are very simple. Housing components vary with vacuums and are based on the company’s perceived view of customer appeal.

AB


16

1. The first step to operating the vacuum is to slide the power switch forward along the handle of

the housing. The power switch initially shows a 0 along the top of the power switch indicating the vacuum is off. In the forward position, the 0 is obscured and a I is shown along the bottom of the power switch indicating the vacuum is on.

2. As the power switch is moved forward, the circuit switch, located on the circuit board, is also moved forward, completing the electronic circuit.

3. Once the circuit is completed, the motor (obscured by batteries) begins operating.

4. With the motor operating, the output shaft of the motor turns (counterclockwise in this photo), rotating the impeller that has been press fitted onto the output shaft. The impeller accelerates air from the center of rotation to the outside. This acceleration creates higher pressure relative to atmosphere at the edge of the impeller and lower pressure relative to atmosphere at the center. These relative pressure differences create a pressure differential across the entire device that drives the air flow for every step. Air entering the front of the device is trying to equalize the lower pressure region by flowing in. Air exiting the rear housing is trying to equalize the pressure by leaving the area of higher pressure.

1

2

3

4

5


17

5. The air that has been driven to the outside of the impeller can escape through holes in the rear impeller housing. It can’t escape sideways as in operation the front impeller housing is on.

6. Air escaping through the rear impeller housing’s back is then directed via stationary fins to the center of the rear impeller housing next to the motor.

7. The air is then directed along the motor, away from the impeller, thus removing excess heat from the motor’s operation. This brings the air from the front of the rear housing to the rear area.

7

6


18

8. The air then proceeds to exit the rear housing through slots cut into the rear housing. This air carries the excess heat out of the housing as well.

9. Meanwhile, on the front end of the vacuum, air enters the impeller through a grate in the front of the rear housing. The grate opens up to the nose assembly when the halves are connected for operation.

10. The reverse view from the grate shows the nose assembly. Air must travel from the dirt cup and through the filter in order to proceed through the grate.

9

10

8


19

11. The view from the dirt cup. Air travels through the crevice tool into the dirt compartment, via the slot shown. The rest of the compartment is sealed with rubber gaskets, and so no dust will escape during device operation.

12. The working end of the vacuum shows where air enters the crevice tool. Due to the sealing of the rest of the device, air my only enter this area, and it will not leave the vacuum until it reaches the vents in the rear housing shown in step 8. This is important as any other air entrances would reduce the air watts of the vacuum and it would not be as powerful.

11

12


20

Charging:

1. The DC power connector is inserted into the charging port in the back of the rear housing, underneath the handle. The charging circuit is completed by this step, and current flows from the house’s alternating current through the wall transformer to the vacuum as direct current. The current charges the Ni-Cd batteries by using electrical energy to re-establish the potential across the battery cells.

2. The LED at position 2 also becomes lit when the vacuum is charging, to inform the customer that the vacuum is indeed charging properly.

1

2


21

Emptying Dirt Cup:

1. The tabs on both sides of the nose assembly are depressed, freeing the latch mechanism. The tabs are kept in the locked position while vacuuming via a coil spring that presses against the cup and tab.

2. The cup lid is then free to rotate about the rivet’s axis. Additionally, springs in the cup lid push the lid open into the position shown in the lower photo by acting on the cup.

3. Dirt is then free to fall from the dirt cup. 4. To close the cup lid, it is simply pressed down until the tabs (1) are locked again.

2

1

3


22

1.1 Filter 24-25

1.2 Crevice Tool 26-27

1.3 Cup 28-29

1.4 Cup Lid 30-31

1.6 Left Release Tab 32-33

1.7 Right Release Tab 34-35

1.8 Tab Springs 36

1.9 Cup Lid Springs 37

1.10 Cup Lid Bottom Gasket 38

1.12 Crevice Tool Housing 39-40

2.3 Left Housing 41-42

2.4 Right Housing 43-44

2.5 Power Switch 45-46

2.6 Filter Release Spring 47

2.7 Filter Release Tab Top 48-49

2.8 Filter Release Tab Bottom 50-51

3.1 Batteries 52-53

3.2 Motor 54-55

3.3 Charging Port 56-57

3.4 Fuse 58

3.5 Circuit Board 59-60

3.6 LED 61

3.7 Circuit Switch 62

3.10 Rear Impeller Housing 63-64

3.12 Front Impeller Housing 65-66

3.13 Impeller 67-68

3.15 Battery Housing 69-70

4.6 Charger 71-72


23

1.1 Filter

The filter protects the impeller, motor, and electronics from damage from dust and other particulates by filtering the air that continues through the vacuum. The elongated cone section increases surface area of the filter cloth, and so improves total air flow and filter life (1). The filter paper is supported by an internal structure (2, seen through filter cloth). This structure and the section that contacts the cup are made from injection molded LDPE. The

filer cloth is made of cotton.

Part Interfaces:

Cup

The outer rim of the filter rests against the cup and keeps it from falling further into the dirt compartment (3).

Right Housing, Left Housing

The back portion of the filter fits snugly against the housing, reducing vortices that could decrease power of the vacuum (4).

1

2

4

3


24

4.49

4.15

3.20

2.10

2.80

Filter Group 35T Johnson


25

1.2 Crevice Tool

The crevice tool is the nozzle through which air and dirt enter the vacuum. It also can extend from the nose assembly allowing it to reach into crevices otherwise unreachable. A bottom extrusion on the device keeps the tool from receding too far into the cup (1). An upper extrusion locks the tool into its fully elongated position (2). Arrows help operator know which direction to move tool to change its position (3).

Part Interfaces:

Cup Lid

The lid contains a slot allowing the crevice tool to slide out from the front end.

Crevice Tool housing

This housing also contains a slot that keeps the crevice tool moving only in the intended direction of travel.

1

2

3


26

2.55

3.70

.75

Crevice Tool Group 35T Johnson


27

1.3 Cup

The cup provides the structure of the nose assembly through which all other parts attach. It has recesses for both cup lid release tabs (1). It also contains two grooves, one on the top (2) and one on the bottom (obscured), that attach to ridges on the rear housing, holding it place. The cylinders that the cup lid rotates are visible, along with the supporting geometry for the cup lid springs (3). The rear hole (at 2) allows the passage of air to the impeller in the rear housing. The front hole is where dirt can be emptied from when the vacuum is full. Visible ridges on the front end make full emptying difficult (4).

Part Interfaces:


Includes slots which fit ridges on the housings that hold nose assembly on

Filter

Geometry of Cup holds filter in place

Cup Lid

Two cylinders allow lid to rotate and limit movement

Cup Lid Springs

Geometry holds springs in place between cup lid and cup

Cup Lid Bottom Gasket

Provides bearing surface to seal cup

Left Release Tab, Right Release Tab

Recesses allow tabs to rotate but not translate

Tab Springs

Holds springs in place and provides opposing surface

Rivets

Two rivets permanently affix cup and cup lid

2

3

1 4


28

4.93

3.84

4.44

2.80

Cup Group 35T Johnson


29

1.4 Cup Lid

Cup lid allows the cup to contain dirt, but then open and dump the dirt out. It also holds the crevice tool and crevice tool housing. The crevice tool extends through the front hole (1). Hidden geometry in the rear connects the cup lid to the cup, allowing rotation (2). The crevice tool holder is attached to the underside with clips and 3 screws.

Part Interfaces:

Cup

Two cylinders allow rotating movement

Rivet

Two rivets permanently affix cup and cup lid

Left Release Tab, Right Release Tab

Slot accepts clip to hold lid in place

Crevice Tool

Limits movement of tool

Crevice Tool Housing

Holds housing in place

Cup Lid Top Gasket

Seals crevice tool housing to cup lid


Provides bearing surface to seal cup

2

1


30

4.16

5.92

4.32

2.40

Cup Lid/ Crevice Tool Housing Group 35T Johnson


31

1.6 Left Release Tab

This tab is one of two parts that hold the cup lid to the cup when vacuuming, but allow them to open to remove dirt. The clip hooks a tab on the cup lid (1). Molded details show the operator to press down on the front of the tab to release the lid (2).

Part Interfaces:

Cup

Cylinders allow tab to rotate around its plugs

Cup Lid

Clip holds cup lid in place

Tab Springs

Hold tab in extended position while vacuuming

1

2


32

1.60

.62.20

Left Release Tab Group 35T Johnson


33

1.7 Right Release Tab

This tab is one of two parts that hold the cup lid to the cup when vacuuming, but allow them to open to remove dirt. The clip hooks a tab on the cup lid (1). Molded details show the operator to press down on the

front of the tab to release the lid (2).

Part Interfaces:

Cup

Cylinders allow tab to rotate around its plugs

Cup Lid

Clip holds cup lid in place

Tab Springs

Hold tab in extended position while vacuuming

1

2


34

1.60

.20

.62

Right Release Tab Group 35T Johnson


35

1.8 Tab Springs (2)

Springs hold right and left release tabs open while vacuuming so that cup lid stays sealed against the cup. Their base, denoted by the larger diameter, rests against the cup and presses outwards (1). This outward force keeps the tab in its extended position unless the operator applies a force to the tab. The tab has an internal nipple that holds the spring in place (2).

Part Interfaces:

Cup

Spring base rests on cup and opposes force on tab

Right Release Tab, Left Release Tab

End of spring presses against these tabs. The tabs have internal nipples to hold spring in place.

2

1


36

1.9 Cup Lid Springs (2)

These springs push the cup lid open when the release tabs are

disengaged from the cup lid. This allows easier emptying of dirt from the cup.

The long arm rests against the cup lid (1) and the shorter arm rests against the

cup (2). Both ends have small circles wound in the wire to prevent the spring

from cutting into the surfaces or the operator. The main winding goes around

the cylinders that the cup lid rotates around (3).

Part Interfaces:

Cup Lid

Provides bearing surface that spring pushes against. This surface moves

when the spring is allowed to unwind.

Cup

Provides opposing bearing surface for spring to push against. This position is fixed.

1

23


37

1.10 Cup Lid Bottom Gasket

The bottom gasket is a silicone molded piece that attaches to the crevice tool housing. It seals along the edge of the cup’s front hole to prevent spillage. It can be distinguished in the photo (1) as the lighter grey piece.

Part Interfaces:

Crevice Tool Housing

The gasket is glued to the housing

Cup

The gasket seals against this surface when the cup lid is closed.

1


38

1.12 Crevice Tool Housing

This housing holds the crevice tool in place and directs air and dirt from the tool into the cup. The 90 degree turn at the entrance to the cup helps prevent any dirt from falling out of the cup (1). It also is connected to both the cup lid bottom gasket and cup lid top gasket to help seal the cup compartment. Two of the three mounting screws can be seen at (2). Additional strength is provided by ribs.

Part Interfaces:

Crevice Tool

Crevice tool rests in main slot of crevice tool housing and directs the tool to only travel in the indicated direction (3).

Cup Lid

Held with 3 screws


Glued to bottom surface

Cup Lid Top Gasket

Glued to upper rim of housing (4).

1

4

3

2


39

3.51

2.80

1.16

R.20

.61

2.30

Crevice Tool Holder Group 35T Johnson


40

2.3 Left Housing

The left housing connects with the right housing to form a protective shell around the motor sub-assembly and all the electric components. It also holds the power switch and the connections for the nose assembly. The screw holes are located on the left housing, some are denoted by (1). Additional features that can be seen include the ergonomic handle (2) and the air vents where air exits the vacuum after traveling through (3).

Part Interfaces:

Right Housing

7 screws

Front Impeller Housing

Ribs support motor sub-assembly

Battery Housing


Charging Port

Ribs support charging port

Power Switch

Ribs and internal geometry hold switch in place and limit its movement.

Filter Release Tab Top

Geometry limits over rotation (4).

Filter Release Tab Bottom

Cylinder provides rotation axis and geometry limits movement.

2

3

1

4


41

9.14

2.56

5.41

.20

Left Housing Group 35T. Johnson


42

2.4 Right Housing

The right housing connects with the left housing to form a protective shell around the motor sub-assembly and all the electric components. It also holds the power switch and the connections for the nose assembly. Feature found on the right housing include the ergonomic handle (1) and the air exit vents (2). The sealing surface for the cup can be seen clearly at (3).

Part Interfaces:

Left Housing

7 screws



Battery Housing


Charging Port

Ribs support charging port

Power Switch

Ribs and internal geometry hold switch in place and limit its movement.


Geometry limits over rotation


Cylinder provides rotation axis and geometry limits movement

1

2

3


43

2.56

9.15

5.41

Right Housing Group 35T. Johnson


44

2.5 Power Switch

The power switch can be operated by a finger to turn the vacuum off or on by its connection (1) to the circuit switch mounted on the circuit board (internal). The switch also displays a 0 (2) or I (3) depending on whether it is off or on respectively. This can inform the operator which state it is in, in case of malfunction of the vacuum. An additional feature seen is the through hole for the LED (4).

Part Interfaces:

LED

Pass-through slot allows led to reach outer housing

Circuit switch

A slot on the power switch operates the switch


Internal geometry limits movement of switch to forwards and backwards

2 3 1 4


45

.27

.21

1.19

Power Switch Group 35T. Johnson


46

2.6 Filter Release Spring

This spring holds the filter release tab in its extended position when no force is applied to the tab. The spring’s base rests against the battery housing and this base does not move. The top of the spring fits onto a nipple on the filter release tab bottom.

Part Interfaces:


Nipple on tab holds spring in place on tab

Battery Housing

Provides static surface for spring to rest on and oppose tab movement


47

2.7 Filter Release Tab Top

The filter release tab top provides a surface for the operator to press down on to operate the filter release mechanism. It also has “filter” inscribed on it to notify user of its purpose (1).

Part Interfaces:


Attaches with 2 screws


Provides limiting surface so tab does not over-rotate at surface (2).

1

2


48

.19

2.40

.58

Filter Release Tab Top Group 35T Johnson


49

2.8 Filter Release Tab Bottom

The filter release tab bottom is the working part for the filter release mechanism. It fits into a cylinder in the right and left housings to provide an axis of rotation (1). It also limits any translating movements. It has a nipple to hold the filter release spring in place (2) and a clip to hold the dirt cup (backside of 3).

Part Interfaces:


Interacts with internal geometry, including a cylinder, to provide correct amount of movement for filter release mechanism.

Filter Release Spring

Nipple holds spring in place on tab bottom (2)


Attaches with 2 screws (4)

1

2

3

4


50

.50

1.46

.15

Filter Release Tab Bottom Group 35T Johnson


51

3.1 Batteries

The batteries store electrical energy from charging and use it to power the motor during vacuuming. Four of the batteries have a neoprene foam on their bottom so that the batteries have vibration isolation from the motor (1). Positive terminal (2). Negative terminal (3). The tabs and wires connect via a solder on terminals.

Part Interfaces:

Battery Housing

A snug fit holds the batteries in place

Batteries

Batteries are interconnected with metal tabs (4)

18 AWG Wire (4)

Connected with metal tabs (4)

3

2

4

1


52

.89

1.65

R.03.40

Battery Group 35J. Horak


53

3.2 Motor:

SRC-540S-7226F

The motor converts electrical energy stored in the batteries into rotational movement that drives the impeller. A positive wire connects to one of the tabs (1) shown on the top and a negative wire connects to the other tab (2). When the circuit is completed, current flows from one wire through the motor and out the other wire. The current flows through the copper windings in the stator, creating alternating magnetic fields in the motor. These magnetic fields attract the copper windings found on the rotor, causing it to rotate. After a certain amount of rotation, the magnetic fields are reversed through a brush mechanism, and the rotor is attracted further to the new magnetic fields. This process repeats itself, causing the rotor to continuing turning in the same direction. This rotational motion is transmitted out of the motor via the shaft (3). The motor is specially designed to run at 9.6V, and the current flow of the circuit was matched to cause a certain number of revolutions per minute that is ideal for the impeller.

Part Interfaces:

24 AWG Wire (2)

These wires attach via soldering to the tabs (1, 2).

Rear impeller housing

Attaches with 2 screws, one has red dye (4) to indicate warranty violations if it is removed.

Impeller

Attaches with a press fit to a knurled surface on the shaft.

4

3

1 2


54

1.40

1.96

.32

.17

.40

Motor Group 35J. Horak


55

3.3 Charging Port

The charging port fits a 5V DC plug (1). It connects to the circuit and allows charging of the batteries via the wall transformer. The front lip fits into the housings and holds the plug stationary (2).

Part Interfaces:


The charging port sits against the housing and is held in place by ribs.

24 AWG Wire (2)

Connected by soldering to tabs (3).

1

2

3


56

.42

.25

.38

.08

.56

Charging Port Group 35J. Horak


57

3.4 Fuse

The fuse protects the electronic components of the vacuum from being destroyed by an excessive current. This prevents loss of the vacuum or fires. The fuse is surrounded by polyethylene tubing that helps protect the glass tube (1). The ends of the fuse are connected to wires vis simple crimp connectors (2).

Part Interfaces:

18 AWG Wire (2)

Uses crimp connectors

1

2


58

3.5 Circuit Board

The circuit board holds the electronic circuit control components and connects them with copper imbedded in it. The main portion of the circuit board is petinax substrate (1). The backside has copper paths connecting the circuits and this is protected by neoprene foam. Components included on the board are a transistor (2), a diode (3), two resistors (4), and the circuit switch (5).

Part Interfaces:


Supported by ribs to prevent jostling

Power Switch

Switch has slot which fits around the circuit boards integrated switch

18 AWG Wire (2)

Soldering

24 AWG Wire (5)

Soldering

1

2

3 4

5


59

.07

2.280

.0701.070

Circuit Board Group 35J. Horak


60

3.6 LED

This light emitting diode (LED) is connected to the charging circuit and turns on when the circuit is complete. The LED color is red (1). The LED is used as a signaling device to the operator as a visual signal that the circuit is complete.

Part Interfaces:


The LED fits into a hole that restricts the LED’s movement out or laterally.

Power Switch

The LED fits into a slot cut in the power switch.

24 AWG Wire (2)

The wires are soldered to the LED positive and negative leads.

1


61

3.7 Circuit Switch

This switch is the physical switch for the operating circuit. The switch is connected to the power switch via a slot cut into the power switch that causes the switch (1) to move along with the power switch. This circuit switch is connected to the circuit board (2).

Part Interfaces:

Power Switch

The power switch has a slot which goes over the plastic switch of the circuit switch.

Circuit Board

The circuit switch attaches via adhesive

1 2


62

3.10 Rear Impeller Housing

The rear impeller housing attaches to the motor (1) to enclose the impeller and make its operation more efficient. It also provides holes to allow air to exit the outside of the impeller (2) and fins to redirect the exited air towards the motor (3). Tabs on the outside connect to the front impeller housing and the battery housing.

Part Interfaces:

Motor

Attaches with 2 screws


Attaches with 2 clips opposite of each other (4).

Battery Housing

Attaches with 2 clips opposite of each other (5).

4

5

1 3

2


63

1.20

.55

3.360

.120

Rear Impeller Housing Group 35J. Horak


64

3.12 Front Impeller Housing

The front impeller housing shields the front of the impeller so that air may only enter the center (1). It also prevents air from escaping the sides, forcing it through the rear impeller housing’s exits.

Part Interfaces:

Rear Impeller Housing

Attaches with 2 clips (2)

Left Housing, Right Housing

The housing is pressed up against the impeller housing when the battery sub-assembly is inserted. This aligns the hole in the front impeller housing with the grate.

2 1


65

1.25

3.37

.07

.33

Front Impeller Housing Group 35J. Horak


66

3.13 Impeller

The impeller creates the pressure differential across the vacuum by accelerating air from its center (eye, 1) to its outside. As it rotates counterclockwise, small fins “grab” air and accelerate it outwards through vanes via their curved shape (2). The increased velocity of the air at the outside edge creates the pressure differential. The impeller is responsible for making a vacuum “suck”.

Part Interfaces:

Motor

Attaches with a press fit onto a knurled surface (3).

3

1 2


67

1.28

2.88

.30

R.28

Impeller Group 35J. Horak


68

3.15 Battery Housing

This part sits on the rear impeller housing and around the motor (1). It holds the eight batteries and interfaces with the rear housing to hold the sub-assembly snugly, so that vibrations do not damage any parts. Arrows (2) indicate battery slots left open for either different vacuum models or future versions.

Part Interfaces:

Rear Impeller Housing

Attaches with 2 clips (3)

Batteries

Pre-formed shape has snug fit with individual batteries

Left Housing, Right Housing

Ribs of left and right housing rest against battery housing

2 2

1

3


69

3.40

1.25

1.00

.210

Battery Housing Group 35J. Horak


70

4.6 Charger

This charger is the AC transformer and power cable for the vacuum. This transformer uses an iron core transformer to convert 120 volt alternating current to 5 volt direct current (1). The transformer also outputs a limited current so that it does not burn any electrical components in the vacuum, for this charger it is 350 milliamps (2). The power cable has a standard 5V DC plug (3).

Part Interfaces:

Charging Port

The plug on the charger’s cable is designed to fit the port.

1

3

2


71

1.62

2.94

.81

4.570

Charger Group 35J. Horak


72

Background Research:

http://home.howstuffworks.com/vacuum-cleaner.htm

This website was read to give team members a background on the operations principles of vacuum cleaners. The website was read to understand major components common to all vacuums. This included a motor, power source, dirt collection bin, and fan (impeller). The website also explained the basic operating principles of a vacuum, and how it creates the apparent suction. The article further gives brief introductions to bag-type vacuums, canister-type vacuums, and ones that use cyclonic air flow.

http://en.wikipedia.org/wiki/Vacuum_cleaner

Wikipedia was used to conduct further research into important considerations in vacuum cleaners. The article gives many different types of vacuums, relating to various purposes. This allowed our team to identify only the few most critical tasks that a cordless handheld vacuum cleaner must perform well in. These tasks include small messes created, cars or other remote areas, and hard to reach places. Further research in the article led to more information on filtering mechanisms. It was determined that current customers are most interested in how effectively a system filters the incoming air and how easy it is to then throw away the dirt. The advancement of cyclonic technology has apparently taken great market share in recent years.

http://www.acleanerplace.com/filtration-101/filtration-applied-to-vacuums/

This final website was used to find advanced information on vacuum filtration. The website validated that filtration technology is very important in modern vacuums and that care must be taken to ensure that it is done properly. The article mentions how high efficiency particle arrest (HEPA) is a new standard in filtration with many customers only considering vacuums with this claim. This standard has created difficulties for many manufacturers as the back pressure from the filter can greatly reduce the power of the vacuum. Some vacuums will not pass all air through the HEPA filter or they may use a HEPA-like filter with a lower cleaning efficiency. These methods would be important in our vacuum as it is much less powerful than many competing vacuums.


73

http://home.howstuffworks.com/vacuum-cleaner.htm

http://en.wikipedia.org/wiki/Vacuum_cleaner

http://www.acleanerplace.com/filtration-101/filtration-applied-to-vacuums/

Patents Researched:

US 8549704 B2

Hand-held cordless vacuum cleaner

Black & Decker Inc.

This patent is for a current competitor’s design. It was studied for primary differences in construction to determine if Black & Decker had different customer requirements than Dirt Devil. After studied, it was determined that Black & Decker believed customers would pay a premium and use a more complex vacuum if it would mean replacing the filter less often. The patent contained multiple methods to increase the life of the filter. This including using multiple filters. The vacuum could be comprised of a primary filter that screens for large particulates and an inner HEPA filter that removes most all airborne particulates. This primary HEPA filter would be pleated to increases surface area, at a cost. Additional improvements focus on methods to clean the filter. This has an actuation mechanism that would drive tabs to rotate the filter so that it would impact ribs. This impact would agitate the filter and dislodge accumulated dirt. A note is made in the patent for using centrifugal forces to remove debris as well. It was determined that Black & Decker wanted to make a more premium vacuum for customers at a higher price point on the basis that it was cleaner than competitors. This is opposite of our vacuum’s requirements were price was more important than cleanliness and maintenance. One improvement that could be possible from this design would be using a pleated filter or a pre-filter and filter system; however, it was believed these improvements could increase cost significantly.

US 20090276974 A1

Cordless Hand-Held Rechargeable Vacuum Cleaner and Charger Unit Therefore

David Khalil (Royal Appliance Mfg.)

Another patent was studied from the same company that makes our vacuum, Royal Appliance Mfg. (Royal Appliance Mfg. is owned by TTI Floor Care North America)


74

This patent was chosen for is dramatically different shape as it shows a different approach to cordless hand vacuums than most on the market.

The device was designed to be charged by a USB cable so that it may be charged from a wall adapter or other electronic devices with a USB port. It is mentioned in the patent that it could be used to clean easily around electronic devices. It was believed that this prompted the high-tech and compact design. Additionally, the device could be used as a blower to remove dirt from places. One such place this could be useful is keyboards. Additional benefits seen were that the device would be much easier to hold in one hand. Disadvantages seen were that the compact design limited the dirt cup size, the motor size, and the number of batteries that could be used. This design showed that our vacuum is too large for some tasks that may be required. It also made us debate the cost benefits of a blower as a design improvement. It was determined that our vacuum would not benefit customers from a significant size and power reduction, and this improvement path was not taken.

Product Patents:

US 6070291 US 6588054 US 6401295 US 6901626 US 6591446 US 6463622 US 6745432 US 7146681

All of these patents are titled “Upright vacuum cleaner with cyclonic airflow”, and do not depict our specific device. Our group was interested in that no patent was listed for a hand-held, cordless vacuum. These patents pertained to the method of particulate removal from the airstream as it moves through the vacuum. These patents show that Dirt Devil has continuously iterated their development of filtering mechanisms since the late 1990s, at a minimum. Dirt Devil uses cyclonic airflow to alleviate the need for dirt bags in filtering exhaust air. Traditional vacuums deposit dirt into a specially designed bag that filters air as it leaves through the walls of the bag. Dirt Devil believed that changing these bags was a significant deterrent to customers. Cyclonic air flow uses the nature of cyclonic airflow to deposit the majority of dirt into a dirt cup before then passing through a filter. Initial deposit of the dirt is necessary to help clean the airstream, as otherwise the filter would clog faster. The patents also describe the technologies of directing exhaust air through the motor sub-assembly and an additional

Figure 1-US7146681


75

filter so that the vacuum expels very clean air. These patents determined that our vacuum’s geometry, most notably that of the crevice tool housing, is critical to the vacuum and could not be changed without an effect on performance.

Manual:

Our team researched the manual in an effort to better understand what Dirt Devil believes are the more complicated features of the product, the safety requirements, and any other important details. The manual is found both in the package and online.

The manual includes an exploded assembly view of the exterior parts. It also includes instructions on how to charge the vacuum, how to use it, and on three of its features. These features are the telescoping nozzle (crevice tool), Gator series dirt cup easy empty, and how to replace the filter. We found that these instructions did not need to go into significant details as most operations were clearly identified on the vacuum itself. The manual seems to include these instructions for those that may feel most comfortable operating only after they read them, such as perhaps older individuals.

The safety considerations of this device are minimal and focus mostly on the electronics. Operators are notified to handle all components with care and practice common electrical safety such as not using near water, disposing of batteries properly, and handling cords with care. Additional concerns include fire safety which states to not vacuum up hot material or in an area with flammable fumes. The final category of safety considerations is to not allow children to use the vacuum as a part is considered a choking hazard.

The manual also presented troubleshooting tips and replacement part information. We found that the troubleshooting tips were not very detailed and probably frustrated many users who found issue with the vacuum as found online. This is especially the case with the battery not holding a charge for very long, as was common among customer reviews. Additionally, the replacement part information is not very noticeable. The filter is a part with a short lifespan, and it is likely most users of the vacuum will need to replace the filter during its lifetime. The part number should be more easily identifiable in the manual.

Overall, it appears Dirt Devil made their vacuum simple enough that they believe most people will not read the instructions. We believe this is a good design goal, but that some oversights occurred in transmitting clear information by trying to simplify too much.

Competition:

Competition research is located and evaluated in the product improvement section. This research was conducted on Amazon.com and product websites. Generally, competition was comparable with vacuums of similar costs. Additionally, the vacuum was compared to a Li-ion vacuum with hopes of achieving similar quality at a much cheaper price point.


76

The improvement to the vacuum was though of and considered using techniques

discussed in The Mechanical Design Process by Ullman. Techniques used come primarily

from chapter 5-8 of the book and center around using a quality function deployment

chart.

1. Who are the customers?

This list was created according to step 1 of the quality function deployment process as

seen in The Mechanical Design Process by Ullman. As described, the customer list was

developed beyond consumers of the product to include the life cycle of the device.

Potential customers include: (consumers)

1. People who live in apartments- Small vacuums are good for small spaces and for quick jobs.

2. College students in dorms- Can use to clean corners and small messes from food.

3. Pet owners- Use to quickly clean up pet hair and other small pet messes.

4. Car detailers- To clean small spaces in cars like under and around seats

Potential customers include: (life cycle)

5. Manufacturer- Must be able to be produced using common production techniques

6. Consumer Stores- Product must be recognizable to store buyers

7. Underwriters Laboratory- Must pass UL tests for safety

8. Marketing Department- Is the vacuum and its features marketable?

It was determined that for our QFD chart is was best to simplify the customer list down

to college students, apartment owners, car detailers, and the market department (Dirt

Devil). This was seen as the best choice as pet owners are more likely to buy one of the

vacuums specially designed for pet hair, like the Bissell Pet Hair Eraser. Furthermore, it

was determined that most designs could be manufactured cheaply, and that choosing

them as a customer would not reveal much information. Consumer stores were not

used as customers as it was determined that since Dirt Devil is an established company,

it would not be hard to find stores willing to buy the product. Finally, Underwriters

Laboratory was not chosen as a customer as all designs could be modified slightly in the

event the vacuum was not approved.


77

2. Customer requirements

This list was created by asking What do the customers want? Due to the short nature of

this project and the limited nature of our ability to conduct surveys or focus groups, we

relied on observation and reviews. Observations came from our and our parents

experience with vacuums. Reviews were found online for our products and their

competitors.

Questions asked of team members and their parents were generated by determining

the most critical information needed to evaluate a vacuum. For our purposes, this

required creating neutral questions to make sure no pre-judgments occurred.

1. Do you use a hand-held vacuum for cleaning?

2. What features to you like best about your current vacuums?

3. What features do you wish your current vacuum had?

4. What is the most valuable information when buying a vacuum?

Reviews were researched on the internet to determine further requirements. It was

determined to look at two places for customer reviews. The Dirt Devil website was used

to gather more information about our vacuum as all reviewers bought specifically from

Dirt Devil. Amazon was used to do comparative analysis as it has the largest sample of

customers of any website and it carries many different types of hand-held cordless

vacuums.

Some customer requirements are:

1. Long battery life

2. Short charge time

3. Batteries memory remains high through product life

4. Strong suction power

5. Lightweight

6. Ability to reach small spaces

7. Affordable

8. Quiet

9. Good looking

10. Includes useful attachments

11. Good filter

12. Dirt does not fall out

Requirements chosen for our vacuum’s improvement were strong suction, long battery

life, lightweight, effective filter, low noise, good looks, inexpensive, and attachments. It

was determined that the vacuum’s ability to reach tight spaces, battery memory, and

charging time were not orthogonal to other requirements already chosen.


78

3. Relative Importance of Requirements

Relative importance is finding how important requirements are to different customers.

It was suggested by Ullman that requirements be ranked by allocating 100 points

between requirements. This method is preferable to ranking individual requirements on

a scale of one to ten, as that method results in too even of a distribution. For our chart,

it is not reasonable to ask actual user that fir our customers, so we had to assume their

position to rank. Both Sten and Justin allocated 100 points to each vacuum requirement

for the four customers used in the QFD chart. Scores from Sten and Justin were then

averaged and normalized to five point distributions. The point distributions are shown

below.

College

Students Apartment

Owners Car

Detailers Dirt

Devil

Strong Suction 20 15 20 25

Battery Lasts Long 15 15 20 10

Light Weight 5 5 10 10

Effective Filter 15 15 15 15

Low Noise 5 10 5 5

Looks Good 5 10 0 10

Inexpensive 30 20 15 25

Special Attachments 5 10 15 0


79

Dirt Devil Gator (Our Vacuum)

-Features

1. $29.00

2. 10.8 Volt

3. 2.8 pounds


80

4. Competition

The competition analyzed for our vacuum consists of three relatively priced vacuums, the Black &

Decker BDH7200CHV 7.2-Volt Cordless Dustbuster, the Dirt Devil Scorpion 6.0V Cordless Bagless

Handheld Vacuum, BD10050RED, and the Shark 12 Volt Cordless Vacuum (SV66), as well as one

premium vacuum outside the price range of our target customers, the Black & Decker BDH2000PL

MAX Lithium Pivot Vacuum, 20-volt.

Vacuum Weight

(lbs) Voltage

(V) Amazon

Rating (1-5) Tools Battery Filter Bagless

Filtration Steps

Dirt Devil Gator 2.65 9.6 3.5 1 Ni-Cd Undisclosed Yes 1

Black & Decker Dustbuster

1 7.2 3.8 0 Ni-Cd Washable Yes 2

Dirt Devil Scorpion

1.8 6 3 1 Ni-Cd Washable Yes 1

Shark Cordless 3 12 3.7 0 Ni-MH Washable Yes 1

Black & Decker MAX

4.3 20 4.6 2 Li-ion Washable Yes 3


81

Black & Decker BDH7200CHV 7.2-Volt Cordless Dustbuster

-Features

1. $18.49

2. 7.2 Volt

3. 1 lb

4. 15.5 air watts

5. 24 Hour Charge time

6. Nickle-Cadmium Battery


82

Dirt Devil Scorpion 6.0V Cordless Bagless Handheld Vacuum, BD10050RED

-Features

1. $24.96

2. 6.0 Volt, 6 Amp

3. 1.8 pounds

4. Nickle-Cadmium Battery

5. 1.5 in width nozzle

6. Quick Flip Crevice Tool

6. Retractable Brush Strip


83

Shark 12 Volt Cordless Vacuum (SV66)

-Features

1. $29.99

2. 12 Volt

3. Nickel-Metal Hydroxide Battery

4. 3 Pounds


84

Black & Decker BDH2000PL MAX Lithium Pivot Vacuum, 20-volt

-Features

1. $79.00

2. 20 Volt

3. 35 Air Watt Suction

4. 4.3 pound

5. Lithium-Ion Battery

6. Pivoting Head

7. Brush Feature

8. Battery not replaceable


85

The competitor vacuums are compared in the “Are the customers satisfied now?” part of the QFD

chart.

5. Engineering Specifications Using the customer requirements, engineering specifications that affect these requirements

were produced. Engineering specifications created needed to be measurable, have a strong

relationship to a customer requirement, and must translate the customer needs into

engineering parameters. Our engineering specifications are:

1. Charge cycles(Number)

2. Charge time(Hours)

3. Run time(Minutes)

4. Suction(Air Watts)

5. Motor Strength(Rotations per minute)

6. Weight(Pounds)

7. Appearance(Percentage who thought above average looking)

8. Price(Dollars)

9. Noise(Decibels)

First specifications are evaluated on their relationship to the customer requirements. This

creates the what vs how chart in the QFD. Each specification was rated either a 9,3,1, or zero in

their relevance to each customer requirement and then compiled in regards to importance for

each customer in the bottom of the QFD.

Next we evaluated specification targets showing each competitor against each other and finding

a target and threshold goal. The target was determined as the most desirable competitor value


86

and the threshold was chosen as the least desirable competitor value. This is seen in the chart

below. If a specification for a model was unknown it was given a value of ‘?’ and should be

found in the future.

Then the specifications were compared against each other to evaluate tradeoffs. This is found on

the top of the QFD chart found below. The biggest tradeoff with most specifications was price,

which is expected because as the quality of parts goes up the price goes up as well.

6. Quality Function Deployment Chart

All of the Data from above was compiled into A QFD chart from Ullman Chapter 6. This data

helps us analyze possible design concepts for our vacuum.


87

7. Possible improvement concepts

Possible improvement concepts were created through the use of brainstorming and searching

the web as outlined in Ullman Chapter 7. All ideas were then processed by the group to

determine if they would address a customer concern and were practical. This refined the ideas

to the list below.

1. Change type of batteries,

2. Put in more energy efficient motor,

3. Place batteries in a place where they can be removed and changed,

4. Use available space to put in more battery cells

5. Dust trap to stop dust from falling out when vacuum is off

6. Add brush attachment for pet hair.

7. Redesign fan for stronger suction

8. Final Three Design Improvements

The goal of our final improvements is to increase the function and performance of our vacuum

while minimizing the price increase so it still appeals to our target consumers.

New Battery Pack

Customer reviews showed our group that the Nickel-Cadmium batteries in our vacuum do not

provide long usage time, have a long charge time, and quickly become weak after a couple of uses.

To address this concern a decision matrix was made comparing possible new batteries.


88

As seen above, Lithium-Phosphate battery cells are the best solution according to our decision

matrix but in reality their high price makes them impossible to use in our vacuum while keeping it in

the price range of our target customers. Therefore we will use the second best option from our

matrix, Nickel-Metal Hydride cells.

The second change we will make will be removing the battery cells from around the motor and

transitioning them to a removable battery pack located in the back of the vacuum.

Changing the battery type from Nickel-Cadmium to Nickel-Metal Hydride and transitioning the

batteries from around the motor to a battery pack in the back section of the vacuum will give us

much more appeal to our target customers by addressing two major customer concerns. First, the

concern that the batteries themselves do not hold a charge for long enough, and that they do not

keep a high charge for enough battery cycles. Better batteries should alleviate both of these

concerns and Nickel-Metal Hydride batteries will be able to do this while not raising the cost outside

of the range of our target customers. All of the customers we earlier identified desire this change as

many of the reviews of the vacuum exemplify. Second, having a removable battery pack in the back

will allow customers to replace the batteries if they lose their charge, as well as give customers the

ability to have a battery pack charging while another battery pack is in use in the vacuum. This

specification will appeal to car detailers in particular as they use the vacuums more time each day

than one battery can provide power for.


89

Attachable Brush

Adding a brush would be an inexpensive way to make our vacuum more attractive to those who

own pets and car detailers, as it makes cleaning hair off of furniture and other fabrics way easier. A

brush could be easily attached to the nozzle extension by adding clips to the nozzle and clips on the

brush. The clips will lock into place when put together and are separated by applying pressure to the

top and bottom of the brush. The brush will be slightly wider than the tube extension. This will

slightly lower the suction but increase the area the brush effects. This is a good tradeoff as the

materials a brush is commonly used to help collect, such as pet hair, are usually very light so strong

suction is less necessary. Adding an attachable brush is inexpensive to do and will make the vacuum

considerably more appealing to customers.

Dust Trap

Adding a dust trap to the vacuum would stop dirt and other debris from falling out of the vacuum

when it is off. The trap works by placing a small door on the back of the nozzle, which will open

when the vacuum in on, due to the air pressure dropping inside the vacuum, and will close from a

small spring with a very small spring constant pushing the door back into place when the vacuum is

turned off. This improvement costs extremely little, just the cost of a plastic door and spring, and

will differentiate the Gator from many competitors in the same price range, as reviews have shown

debris falling out while the vacuum is off as a common problem among multiple models.


90


91

Contents:

Quotes 92

Contract 93

Meeting Minutes 94-97

Health Assessments 98-104

Final thoughts 105

Quotes:

Troy: “We all worked together without many issues, but we did not collaborate with each other as much as we could have.”

Justin: “I was happy that all team members got along and we avoided the doom Bob warned us of for having a 3 and 1 group.”

Sten: “Pretty good performance, given that we are getting the project done 24 hours early and we are proud of it.”

Jace: “The team was pretty good about doing what they needed to do, but we all preferred to do our parts on our own.”


92

1. Get all assignments done by deadlines in Gantt charts.2. Have all members participate equally.3. Collaborate on all major decisions.4. Meet all criteria for A quality projects.5. Have all Creo models accurate and consistent for needed purpose.6. Be able to reassemble vacuum cleaner.

1. JW2. SL3. JH4. JW5. TJ6. JH

1. Have everyone produce A-quality work by introducing "wow" factors.2. Have everyone understand each product's full operation.3. Have everyone able to use Creo at an advanced level.4. All team members meet deadlines for projects list in Gantt charts.5. Be open to other's ideas by listening to ideas before decisions.6. Have at least 1 team meeting a week with full attendance.

JWJHTJSL

1. Bi-weekly meetings for clarity and team performance assessment.2. Discuss all major decisions to hear all views and build consensus. (Tie-breaker by team coordinator)3. Discuss issues that come up, and do not hold in any unresolved issues.4. Use independent moderator (Bob) for unresolved issues.5. If all else fails, bare knuckle boxing...

35 1/24/2015

Justin Weinmeister

Justin Weinmeister Coordinator, organizational reports JW 970-631-7348 [email protected]

Troy Johnson Creo coordinator, assembler TJ 970-218-0464 [email protected]

Jace Horak Creo worker, hardware JH 970-218-1338 [email protected]

Sten Larson Innovator, editor SL 303-910-3567 [email protected]

7. Add wow factors to work when it is appropriate. 7. SL

7. All members actively check their "buddy's" work weekly.


93

Team Meeting Minutes: Group 35 Date: 1/24/2015

Attendance:

Justin Weinmeister

Jace Horak

Troy Johnson

Sten Larson

Agenda:

1. Finish individual assignments for assignment 2

2. Collaborate on Russian Moon Team Health Assessment

3. Develop team contract

4. Assign project leader

Discussions:

Meeting lasted 1.5 hours and discussed project as well as personal backgrounds. Personal

backgrounds were discussed to break the ice, find strengths of team members, and familiarize ourselves

for a healthy team relationship. A contract was developed that covered major responsibilities, duties of

individual members, and conflict resolution strategies. It was determined everyone believed the PTC

Creo files would be most time consuming for the project.

Decisions:

1. Agreed to contract rules on conflict resolution

2. Assigned Justin Weinmeister as project leader

Actions Required: Resource Deadline

Buy Vacuum JH 1/28/2015

Pre‐disassembly Research SL, JW 1/29/2015

Next meeting:

1/29/2015


94


Attendance:

Justin Weinmeister

Jace Horak

Troy Johnson

Sten Larson

Agenda:

1. Test vacuum performance versus upright

2. Disassemble vacuum

3. Create bill of materials

4. Assign final project tasks

5. Distribute vacuum parts

Discussions:

Meeting lasted 2 hours. Testing revealed the vacuum was more powerful than thought. More

team conversation familiarized ourselves and helped to develop a better working relationship. It was

decided most parts could be completed separately until the final week.

Decisions:

1. Troy would model exterior parts and Jace interior parts

2. Sten would work on project improvement, focusing on battery

3. Justin would create product decomposition


Model parts in Creo JH, TJ 2/17/2015

Improvement SL 2/24/2015

Product Decomposition JW 2/14/2015

Next meeting:

2/3/2015


95


Attendance:

Justin Weinmeister

Jace Horak

Troy Johnson

Sten Larson

Bob Thilmont

Agenda:

1. Discuss team contract

2. Discuss project plan

3. Receive advice on best practices for team health

Discussions:

Meeting lasted 0.5 hours. It was determined that our team contract was well developed and

required no further action. It was mentioned that a team structure of three familiar people with one

unfamiliar is most troublesome combination in class. It was also discussed that this member, Sten

Larson, was also assigned the most points of any individual on the team. The assignments were justified

based on strengths and hour distribution, and would not be likely changed; however, it was noted that

total hours worked must be carefully monitored. This duty was given to the project leader.

Decisions:

1. Agreed to carefully watch hours assigned across team members


Watch team hours JW 3/4/2015

Next meeting:

3/2/2015


96


Attendance:

Justin Weinmeister

Jace Horak

Troy Johnson

Sten Larson

Agenda:

1. Discuss progress on all parts and identify areas still needing work

2. Finish any work and edit

3. Edit all work

4. Final Team Health Assessments

5. Assemble Project

Discussions:

Meeting lasted 4 hours. Most all parts had been finished with minor detailing needed for PTC

Creo files, project pages i. e. table of contents, and some more work on the recommended

improvement. After this work we used the buddy system to double check parts and found some errors.

Out final team health assessments went quickly as the team works well together and the assembly

finished out first project.

Decisions:

1. Agreed that this project was hard and we need to follow improvements we recommended

to ourselves for project 2.


Relax JW, JH, SL, TJ Forever

Next meeting:

N/A


97

Team Health Assessment Your assessment team members:

SA= Strongly Agree A = Agree N = Neutral

D = Disagree SD = Strongly Disagree NA = Not applicable

Measure SA A N D SD NA1

4

5

7

8 ✔

9

10 The team took time to develop consensus by discussing the concerns of all members to arrive at an acceptable solution.

11

12

16

18

19

20

Remedies for improving the Neutral (N), Disagree (D) and Strongly Disagree (SD) responses:

Based on page 77 of The Mechanical Design Process (4th edition) By Professor David G. Ullman © 2008, McGraw-Hill

Justin WeinmeisterTroy JohnsonJace HorakSten Larson

Date of assessment:

1/29/2015

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

Our team has yet to do much of any work and so some facets can't be judged. At thispoint we all seem to agree on common practices for our assignment and the futurelooks good for an A. This first health assessment was done with the entire team.

Troy Johnson, Sten Larson, Jace Horak, Justin Weinmeister


98





4

5

7

8 ✔

9


11

12

16

18

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20




Date of assessment:

2/12/15

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

9. Some conflicts have not been aired and people tried to work through them, this holdsback efficiency of the group.16. The team is behind schedule.18. Some group members are behind schedule and so their word is not full proof rightnow.19. No team members have helped those behind right now as we do not want tocontribute more work than others.

Jace Horak, Justin Weinmeister, Sten Larson, Troy Johnson


99





4

5

7

8 ✔

9


11

12

16

18

19

20




Date of assessment:

3/2/2015

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

10. time was an issue for mostly everyone. with the different schedules it was hard tocommunicate effectively. a better communication system would have helped

Jace Horak


100





4

5

7

8 ✔

9


11

12

16

18

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20




Date of assessment:

3/2/15

✔

✔

✔

✔

✔

✔

✔

✔

✔ ✔

✔

✔

✔

✔

9. Each member should voice any problems that they are having so other membershave the chance to offer assistance.16. Start tasks on the date shown in the Gantt chart and no later.

Troy Johnson


101





4

5

7

8 ✔

9


11

12

16

18

19

20




Date of assessment:

3/2/2015

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

12. Coming in not knowing everyone, i don't really know everyones strengths andweaknesses and seeing everyone more will help me feel more comfortable.16. I feel like everyones personal parts are done except i still need to finish up mywork, as well as the style we want to put everything together in should have beentalked about from the start, and talking about that at our next meeting should help.

Sten Larson


102





4

5

7

8 ✔

9


11

12

16

18

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20




Date of assessment:

3/2/2015

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

9. Some conflicts have been avoided rather than confronted.16. The team ended up far behind schedule, most likely my fault.18. People will get their work done, but the work may be rushed at the last minute.Additionally, some of the work has not lived up to the A standard in the contract.19. No team members have been especially vocal about helping others, though we dotry when possible.20. Everyone works hard, but they may not be putting enough care into the work.

Justin Weinmeister


103





4

5

7

8 ✔

9


11

12

16

18

19

20




Date of assessment:

3/2/2015

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

9. Conflicts need to be aired faster.11. Ask for others opinions before making important decisions.

Justin Weinmeister, Sten Larson, Jace Horak, Troy Johnson


104

Health Assessment Overview:

As can be seen our initial two health assessments were very positive. At the end of the project, most everyone agreed that we had had a few errors when it came to communication and getting work done. The team consensus, though, is that these errors were minor and pose no serious challenge for the upcoming project 2. We look forward to winning.

Final thoughts:

This project tested our group’s planning skills and helped us develop new ones along with teamwork skills. The only issues to come out of the project revolved around the group’s independence and full trust in one another. These issues were minor and easily rectified. As such, no major issues ever developed that threatened our ability to finish the project at the quality level we desired. Our group believes the greatest teamwork skills we developed revolved around communicating with individuals. We learned to communicate faster when problems developed in our work, as our teammates may be able to finish the task faster.

Finally, we learned much more about hand-held cordless vacuums than any sane person would ever want to know, but we confidently believe that Dirt Devil (or whichever one of the many parent companies does the actual design) had an effective team working behind the Gator 9.6V, as it is a well-designed product.

Jace Horak

Troy Johnson

Sten Larson

Justin Weinmeister


105

FRANÇAISCET ASPIRATEUR A ÉTÉ CONÇU POUR USAGE DOMESTIQUE SEULEMENT.CONSIGNES DE SÉCURITÉ IMPORTANTESLorsque vous utilisez un appareil électrique, vous devez toujours respecter certaines consignes de sécurité, dont les suivantes :

LE METTRE EN MARCHE.

DES MALFORMATIONS CONGÉNITALES ET ENDOMMAGER LES ORGANES

MANUAL DE INSTRUCCIONES ®

INSTRUCTION MANUAL ®

®

prepaid

®

®

®

1-113927-000 R1

1-113927-000 R1

1-113927-000 R1

MC

CHARGING

CHARGEMENT

1.

1.

1.

1.

CLEANER DESCRIPTION

1.

3.

1.

1

1

7

7

6

6

9

9

9

9

11

11

4.

GENUINE

GENUINE

GENUINE

2.

1.

Appendix AProject 1 Mech 202 Group 35

106

ESTA ASPIRADORA ESTÁ DISE—ADA PARA USO DOMÉSTICO SOLAMENTE.

INSTRUCCIONES DE SEGURIDAD IMPORTANTESGUARDE ESTAS INSTRUCCIONES

USARLA.

PLOMO O COMPUESTOS DE PLOMO ACERCA DE LOS CUALES SE HA

DESPUÉS DE SU USO.

GUARDE ESTAS INSTRUCCIONES

ESPA—OL

GARANTÍA LIMITADA

®

®

®

® o en otras au

GARANTIE LIMITÉE

®

®

GUIDE DE DÉPANNAGE

UTILISER UN FILTRE DE

1.

surplus de saleté et de

et la saleté, ou secouer le

3. 4.

RETRAIT ET REMPLACEMENT DU FILTRE

2.

para polvo para poder

USO

CARGA

1.

1.

DESCRIPCIÓN DE LA ASPIRADORA

1.

residuos del contenedor

3.

1.

1

7

6

99

11

4.

2.

se encuentran en el reverso

TOUT AUTRE ENTRETIEN DOIT ÊTRE EFFECTUÉ PAR UN REPRÉSENTANT AUTORISÉ

®

®


107

Design Structure Matrix

A B C D E F G H I J K L M N O P Q

Purchase Vacuum

A A

Research B X B Disassemble C X X C Bill Of Materials

D X X D

Creo Model E X E X Creo Drawings

F X X F

Part Description

G X X X X G

Exploded View

H X H

Reassemble I X X I Cover page J J Cover Photo K X X K Operation Description

L X X X L

Improvement M X X X M Teamwork Review

N N X

Review Parts O O Gantt Chart P P Assemble Report

Q X X X X X X X X X X X X Q

This design structure matrix was used to help identify the order of tasks for our project, specifically, designing Gantt chart. The task list was created from the initial Gantt chart construction, and it was evaluated. It was determined that most tasks could be done in the order listed, additionally; some tasks had few dependencies and could be created quickly. Dependencies listed as red were not known at the creation of the design structure matrix. These could have caused serious issues, but they were not factors as the tasks were already in the correct order. Only two tasks were not fully in the correct order. These were the Creo model and the teamwork review. The Creo model required the improvement, but only in its last stages, so most of the model was created before going back and adding the final features later. The teamwork review and report assembly were mutually dependent, and had to be done at the same time.

Appendix B


108

Website List

http://www.amazon.com/Black-Decker-BDH7200CHV-7-2-Volt-Dustbuster/dp/B00B8I23XA/ref=sr_1_7?s=vacuums&ie=UTF8&qid=1424327557&sr=1-7&keywords=handheld+vacuum

http://www.blackanddecker.com/power-tools/BDH7200CHV.aspx

http://www.amazon.com/Dirt-Devil-Scorpion-Cordless-BD10050RED/dp/B002D47XOC/ref=sr_1_24?s=vacuums&ie=UTF8&qid=1424541289&sr=1-24&keywords=handheld+vacuum

http://www.amazon.com/Shark-Volt-Cordless-Vacuum-SV66/dp/B00IJLIZNQ/ref=sr_1_22?s=home-garden&ie=UTF8&qid=1424540852&sr=1-22&keywords=handheld+vacuum

http://www.amazon.com/Black-Decker-BDH2000PL-Lithium-20-volt/dp/B00IOEFBKS/ref=sr_1_5?s=vacuums&ie=UTF8&qid=1424327557&sr=1-5&keywords=handheld+vacuum

http://blackanddecker.com/power-tools/bdh2000pl.aspx

Appendix C


109




http://www.blackanddecker.com/power-tools/BDH7200CHV.aspx









http://blackanddecker.com/power-tools/bdh2000pl.aspx

Documents

Mech 202 Project 1 Report