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escuela técnica superior de ingeniería - IIT

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1. 163 164 Appendix AE Low Resolution Prototype Construction Process Result and Customer Interview Step 1 We used play dough to make the brush We thought it is a great idea because play dough is soft when we open the jar and it allows us to stick copper wires into it It gets hardened after it is exposed to the air for a certain amount of time After we opened the jar we tried to shape the clay to be like the brush we currently have Step 2 We stripped off the coat and got the copper wires from it We twisted a little bit so that they do not get separated and stay together Step 3 Finally we stick the copper wires into the clay We let it sit for two day 165 Current Bru 1 nr Prototype 1 Prototype 2 le Current Brushwheel Top View 166 Prototype 2 ligned in a straight line Top view of Prototype 2 Front view of Prototype 2 indicates it is longer bristle Prototype 1 A aligned in a straight line Top view of Prototype 1 Front view of Prototype 1 167 Prototype 1 on the grill Short bristle cleans the top part of grill Long bristle cleans the side of grill Prototype 2 on the grill 169 Customer Feedback just brushing the top I do not think the long short design prototype 2 offers more benefit than the brushes being all the same length Customer 2 I like prototype 2 for the grill cleaner because it cleans down
2. Update Specification S DeL soe rerit eet ede CDOS ea aio Problem Statement A PHASE I CONCEPTUAL RE DESIGN 4 50 1 6216519571 6011165 VE I EU EE e LUN rod ERAN E Mind IVI ADS Functional Background Information ssccccccssssssssccccssssssssccccssssssscccscssssssccsscesssssccsscesssscscosseesess Morpholosical Matrix an Theory of Inventive Problem Solving TIPS ssscesicccscscccssvceccvcecasesessecsevsesconscsenscsestecaes vedesecensssessseuses O EN EID OPE LUE L w Resolution POLO BEG o eno bero eoe see satis ces sek aces uk E ve ul een A Order ot Mastiude ihn 5107661116411001 5176615 p e vs e is Puch Chart ara AS ES O DE M Problem Statement irr Mattei EDE Dee ta TES PHASE III PARAMETRIC RE DESIGN ccsccsoscsosccscscovcscecescccsescccccscoscscccescescsonsessscccssovess Parametric Interests ninia ains Experimental Modelos aio O CATCH AGO Theses eos a E ER OE ARAN SSE ED RS soba cu ved IV 19 Statistical Analysts A Ruinen Failure Modes and Effects Analysen RR IE LE ERE ERN E ende Desien A einer Desien for Manulactunns sera Desien for Environment asses ENED ee Revised Mater 22 2 E a AO Final Proto Pei eiii CONCLUSION ge RENNEN ANNOTATED BIBLIOG
3. So 103 Name JO OA FY od Rate your grilling experience level I 2 3 4 5 Appearance 1 2 3 y Comments 2 Noise tae Ike a tangan d 1 2 32 4 3 Lommen wull ll rithe use bruth o NM 4 Easv to hold 1 2 3 4 5 Comments EN ul be n 4 han KH 77 ue t PLE iy PATO MEET Easv to clean the 07111501 1 2 3 2 5 Lomment Easv to operate fieure out l 2 3 4 5 Comments Value 130 1 a 3 4 5 ey A etre Jio tir N or P ZE X 3 2 Overall rating 1 3 4 5 EE O O A ee AAPP 5i do vou tike about the GrillBot Mths Wis UA Pr Er What do vou NOT like about the Grill Bot Y 2 M net What would vou change aide al prte derme Ne ty nyh Would vou buv it Whv whv not not ir Vo T O pres 104 Appendix F Suggested Price vs Experience Suggested Price vs Experience Ur N y 5 9615x 13 846 Ur O O U Un U NS V WW v Q Q Lo u u 89 89 3 U N O Ur m O u 3 Grilling Experience level 1 5 105 106 Appendix G Customer Interview Sheet Data EN ZEE 3 meme A 3 ww 1 4 Bem 3 s wonm 3 tary elem 3 7 Easy to operate figure 4 out 3 ww Oi what I expected Noise is very loud it hits the edges and Make quieter 11 sh
4. General Tolerances mm 0 005 FROM TO z 0 25 0 5 25 125 10 8 125 300 1 0 300 1 5 Use standard thickness variation capability do not over tolerance Use standard dimensional variation capability g do not tolerance Y Figure 14 7 Injection molded part design guidelines 202 Appendix AR Design for Environment DFE Guidelines Principle A Ensure sustainability of resources by 5 9 21 Specifying renewable and abundant resources 4 5 7 8 25 Specifying recyclable or recycled materials especially those within the company or for which a market exists or needs to be stimulated 5 9 16 25 28 32 Layering recycled and virgin material where virgin material is necessary 7 25 or of ed materials 7 25 ret penas components across models 6 8 16 31 32 Specifying mutually compatible materials and fasteners for recycling 4 6 8 16 25 28 32 Specifying one type of material for the product and its subassemblies 6 7 9 16 24 25 28 30 33 ame SY zt u in 24 25 g renewable forms of er 5 Principle B Ensure healthy inputs and outputs by 21 24 a Installing protection against release of pollutants and hazardous substances 7 25 non hazardous and otherwise environmentally clean substances especially in regards to user health 5 7 9 25 28 32 12 Ensuring that wastes are water based or tiodegradable 5 6 16 30 13 Specifying the clean
5. 1 112 Customer Needs Summary 1 User Interactions 141 Easy to figure out 2 _ 1 2 Quick and simple operation 3 13 Easy to hold and place on grill f 2 1 4 Easy to disassemble mE ENS NIIN 1 4 1 5 1 6 p 2 3 Portable 3 4 1 Lightweight 2 4 Effectiveness Effectiveness __ 4 4 Does not damage gill _ 4 5 Operates autonomously as a robot _ 5 1 Reasonable purchase cost 52 Good function for the price 3 _ 5 3 Long lasting life of components 2 5 4 Economical to operate 1 2 lu um um ue EN CENE NENNEN 113 Relationships Strong Positive 7 Medium Positive _ Appendix H House of Quality HOQ Medium Negative Strong Negative Customer Perception Engineering Characteristics Relative Importance Mass of Grillbot Cost of Grillbot Customer Attributes Direction of Improvement Units i asy to hold and place on grill asy to disassemble asy to clean brushes User Interactions uiet noise level ing noises nformative beeping notifications ightweight ong battery life horough cleaning ast cleaning TIT IMO 0 m m DIO o gt c Iio 2 13 Y 2 2 o 2 lt 74 lt Q M O Oo lo o lt fu O 0 io O A 5 Q 2 9 o oio D o Q o o
6. A Operation wos Operating Noise 5 4 04 09 15 b Noise level of beeping after shutdown 40 25 ds Al 15 02 15 w ExpeetedCostofprodut TJ lt O 3 m Industrial Redesign Avenue Sheets AG Specification IX Append 186 Vaue TergetValue Unis TResponsibiy Test Verification TAT Verity wih dimensions gen by the Engineering sketch Lewes Hw voe woms o em 5 2 mm a Measure with are 04 04 15 D tetaldeaningareaofbrush 22302 365364 mm AM Calculate from dimensions of the hristles 04 0415 D totalareaofgrillcleaned 1 26 251 m Al Calculate from rotational speed cleaning time and cleaning area 04 04 15 XP Rotation Rate of Wheels 3 13 3413 cycles per second EE ME Verify with output torque of motor Leyupns 3 mas 533 43 mm A Measure Weight with a digital weight scale 04 04 15 D Test through Tensile Strength Test 04 09 15 from customer interviews 04 04 15 D Cleaning Time 30 60 minutes Al Measure time required to clean the grill with stop watch Functional Redesign Avenue Appendix AH Pugh Chart Better 0 Same Concept Variants Modifying Brush riteria i urchase cost leaning time minutes evelopment risk of OEMs and vendors to source parts urability months of operatio
7. Appendix AL Experiment Results Table 1 Depth of the penetration Lf Weight Length Trial X 1 X 2 Yl 1 Y1 2 inches inches Table 2 Area removal Weight Length Trial X 1 X 2 Areal Area2 in in 194 Appendix AM Statistical Analysis Depth of Affect Brush Length Average Effects Surface Area Removed Weight 195 Surface area removed Bristle Length Average Effects ba a 31 jin ce Area E Surta 196 Multiple R 0 230982 0 672414 0 785243 0 618161 Table R values for control variables Regression Surface area 0 229938 0 181012 0 41095 mer PE Table Coefficient Values for surface area removal 197 198 Current Situation Current Detection Steps faulty electrical connection Current meter 2 2 6 24 Have a sensor to shut down the device when it overheats 2 6 2 24 Weakening Solder Current meter ___ 2 2 2 8 Solder neatly S 2 r 2 4 verse Visual 1 6 2 12 Usea stronger material to prevent wear misuse visual 7 7 49 Use a stronger material to prevent wear Failure Cause fatal fal gt Euge aaa a Urea more cien motor or have the toppings be l Motor Longevity test 6 4 4 6 0 24 ee wear amp tear poor assembly faulty equipment Tr a Improper installation physical damage corrosion rity tes 6 414 9 and material buil
8. COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ACAD GRADO EN INGENIER A ELECTROMEC NICA ESPECIALIDAD MEC NICA APPLICATION OF MECHANICAL ENGINEERING DESIGN METHODOLOGY TO REVERSE ENGINEER AND RE DESIGN A GRILL CLEANING ROBOT Author Mar a Reina G mez Acebo Director Christopher G Rylander University of Texas at Austin Madrid May 2015 AUTORIZACI N PARA LA DIGITALIZACI N DEP SITO Y DIVULGACI N EN ACCESO ABIERTO RESTRINGIDO DE DOCUMENTACI N 12 Declaraci n de la autor a y acreditaci n de la misma El autor D Mar a Reina G mez Acebo como Estudiante de la UNIVERSIDAD PONTIFICIA COMILLAS COMILLAS DECLARA que es el titular de los derechos de propiedad intelectual objeto de la presente cesi n en relaci n con la obra PROYECTO FIN DE GRADO DE APPLICATION OF MECHANICAL ENGINEERING DESIGN METHODOLOGY TO REVERSE ENGINEER AND RE DESIGN A GRILL CLEANING ROBOT 1 que sta es una obra original y que ostenta la condici n de autor en el sentido que otorga la Ley de Propiedad Intelectual como titular nico o cotitular de la obra En caso de ser cotitular el autor firmante declara asimismo que cuenta con el consentimiento de los restantes titulares para hacer la presente cesi n En caso de previa cesi n a terceros de derechos de explotaci n de la obra el autor declara que tiene la oportuna autorizaci n de dichos titulares de derechos a los fines de esta cesi n o bien que retiene la facultad d
9. a very disturbing noise The general consensus found on Amazon is that it cleans very well as if someone had cleaned it himself or herself with a wire hand brush Most customers say they were quite impressed although they also found a few drawbacks The Grillbot is loud so it would not be appropriate to use late at night if you have neighbors nearby It does not take long to clean up as the brushes can be put directly in the dishwasher but they wear out with time and must be replaced Overall customers seem to think it is a good product but wish it would be improved or available at a lower price The information in these reviews 15 useful because it gives us a good idea of what kind of questions to be asking our interviewees to get a better view of the key properties that require our attention The information also gives us an idea of what to expect from long term usage in a way that we may not have been able to witness or ask in our interviews The customer comments provided us with useful information regarding the performance and durability of the Grillbot after extended use up to four or five months With this data we can redesign the Grillbot to improve on 73 the points that have made these customers unhappy and increase customer satisfaction with the product 2 Consumer Reports 2014 Grillbot grill cleaner Retrieved from http www consumerreports org cro news 2014 04 noisy grillbot could be better at fighting grime
10. 2 US008947024B2 10 Patent No US 8 947 024 B2 45 Date of Patent Feb 3 2015 56 References Cited U S PATENT DOCUMENTS 3 106 192 4 EOD IES 27 307 66 4 549 151 A 101985 Kaneko 332 110 5 490 370 A misa NL 2 1996 McNair et al 5 744 021 A 4 1998 Makaran 318 400 34 2002 0014870 AI 22002 Krotsch et al 318 254 2008 0136376 6 2008 Nebrigic et al 320 136 2009 0302815 Al 12 2009 Tanzawa ses 323 282 20100218385 A1 92010 Mang etal 30 216 20100283332 AI 11 2010 Toukairin et al 310 50 20100298983 A1 11 2010 Beste etal 700 276 2011 0068723 Al 3 2011 Maiocchi ssns 073 201 10186318 AI 82011 Ichikawa 173 176 20110227430 Al 9 2011 Omorietal 310 50 2012 0067608 AL 3 2012 Heinzelmann et al 173 217 2012 0191250 Al 72012 Iwataetal 700 275 2013 0069613 AL 3 2013 Nakase et al 323 284 cited by examiner Primary Examiner Eduardo Colon Santana Assistant Examiner Devon Joseph 74 Attorney Agent or Firm Walter Ottesen P A 57 ABSTRACT An electric motor includes an arrangement of windings pro vided for driving the rotor with the windings being connected to an energy source to develop torque which drives the rotor The electric circuits of corresponding ones of the windings each ha
11. To do List 4 6 15 4 6 15 0 Gantt Chart 4 6 15 4 6 15 0 Develop Experimental Experimentation 4 6 15 4 12 15 0 Back of the Envelope 4 13 15 4 16 15 0 FMEA 4 15 15 4 19 15 0 Design for Assembly 4 20 15 4 24 15 0 Design for Environment 4 20 15 4 24 15 0 Preliminary Drawings 4 20 15 4 24 15 0 131 Appendix V Picture of the Wall The wall where the device is colliding with 132 Appendix W Mind Maps Steel Change material Increase shell thickness More than 0 minutes Longer cleaning duration Add weight Clamp attachment Increase friction Decrease speed Cleaning Change direction more often dispenser fluid Water Soap NH Make them Degreaser longer 133 Improve For functional redesign avenue Resonant frequency Ultrasonic cleaning B gt gt Reach nn corners Copper steel plastic Different lengths and thicknesses Shorter bristles Bristles pointing Longer radially bristles For industrial redesign avenue Longer bristles Rubber increases cleaning area Decrease speed Adding bristles on Plexiglas the edge of Cart brushes ee New Motors absorbing makes less Material N noise Motors 07 cameras Avoid Collision Use earplugs Radar es Reduce Noise Externally Probes Stand far away from grill Body Add Material Add pa
12. e Radar Echolocation 7 Bracket to secure lid 8 Make lighter 149 Functional Redesign Avenues Improve Cleaning Water dispenser on the radial or axial part of the brush Water dispenser coming out of the robot Thicker shell Different material Magnetic attraction Added mass Material Length Attachment method Geometry of the bristle Toothbrush pattern Ultrasonic Vibration Speed Time duration 150 1 Fluid 2 Down force 3 Brush Consistency 4 Ultrasonic Vibration 5 Number of Passes Appendix Y Analogies for functional redesign avenue Car Wash Car wash is a facility used to clean the exterior of automobiles One of the types of automatic car wash uses giant rotating brushes to clean cars The brushes are located on the sidewalls and in the ceiling of a tunnel When the car goes through the tunnel the brushes are spinning While the brushes are spinning soap is dispensed and then water is sprayed to rinse it off Signature n d Car wash and Grillbot use a similar cleaning method rotating brushes touch the surface Therefore if we also use water while the brush is spinning 1t would definitely improve cleaning Using water and cleaning fluid could sooth the dirt on the grill and brushes would be able to get rid of food particles easter am m um E RN 151 Toothbrush A toothbrush is an oral hygiene instrument to clean teeth and gums It is a stick with a t
13. A 2014 Concepts of Oral Hygiene Maintenance that Would Apply for the Different Groups of Patients In C A Migliorati Diagnosis and Management of Oral Lesions and Conditions A Resource Handbook for the Clinician pp 123 136 InTech Signature Series n d Retrieved April 5 2015 from http www belangerinc com signature Soap how does it get things clean n d Retrieved April 6 2015 from Planet science http www planet science com categories under 11s chemistry chaos 2011 06 soap how does it get things clean aspx Ultrasonic Cleaning 101 n d Retrieved from BLUE WAVE ULTRASONICS http bluewaveinc com ultrasonic cleaning 101 81 82 APPENDIX Appendix A To do List and Gantt chart for Phase I Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed To Do List Phase 1 To Do List Gantt Chart Product Brainstorming Product Selection Background Literature Textbooks 2 Patents 3 Competitors Product Information Customer Reviews General Sources Put it all together Customer Needs Analysis Form Questions Perform Interviews Create Customer
14. Appx M begins with the material input of hand and the information signal to turn it on and set the time From there the information is coupled with an electrical energy source inside the circuit board and that energy is sent forward to the motors LCD or speaker On the way to the motors the electrical energy is transmitted through the motor wires Next the motors convert the electrical energy to rotational mechanical energy During the conversion process some energy is lost as waste heat and waste acoustic energy Next the rotational mechanical energy is sent to the brush wheels which convert the rotational mechanical energy to translational mechanical energy to clean the grill The brush wheels take a dirty grill as a material input and send a cleaner grill and food crumbles as the material output That process results in acoustic heat and translational energy losses The electrical energy and information that goes to the LCD shows the time left as well as battery life as information outputs By showing that information the LCD releases optical energy A temperature sensing device likely a thermocouple converts heat into electrical energy which gives the controller a temperature reading This temperature signal turns off the device when it 1s over 250 degrees F the melting temperature of standard plastics Finally the speaker produces acoustic energy in order to indicate excessive environmental temperatures as well as when the Grillbot
15. Assistant Examiner Elizabeth A Burkhart 74 Attorney Agent or Firm Dinsmore amp Shohl LLP 57 ABSTRACT A foodware article having a multilayer stick resistant ceramic coating The foodware article of the present inven tion includes a metal foodware article having an inner food contacting surface and an outer surface a bonding layer deposited on the food contacting surface and a first layer of Ti Al Cr N deposited adjacent to the bonding layer There is optionally a layer of chromium nitride deposited adjacent to the first Ti Al Cr N layer and a second layer of Ti Al Cr N deposited on the chromium nitride layer These layers can be repeated as many times as desired The Ti Al Cr N layer is generally the top layer of the multiplayer coating The coating is stick resistant scratch resistant thermally stable corrosion resistant and color stable The foodware is suitable for use with both salty based and acidic based foods A method of making such a foodware article is also disclosed 21 Claims 2 Drawing Sheets 545 335 330 325 320 310 315 88 a2 United States Patent Ge METHOD OF MAKING A STICK RESISTANT MULTI LAYER CERAMIC COATING Inventor Molly Mo Hui Ge Arlington Heights IL US Assignee National Material L P Elk Grove Village IL US Notice Subject to any disclaimer the term of this patent is extended or adjusted under 35 U S C 154 b by 337 days Appl No 11
16. Lastly concept variant 5 details the design and results of including a high velocity water jet at the base of the Grillbot This addition extends beyond the penetrability of the brushes to include the spaces between the grille bars The force applied from a fluid jet at 10 m s is about 22 N more than 20 times the forces applied by friction The calculations for Order of Magnitude can be found in Appendix AF Specification Sheets Industrial Redesign Avenue After selecting our avenues for improving the Grillbot s design we could define more finite specifications to help reach our product s requirements For the industrial redesign avenues many of the original specifications are still valid We decided mostly on adding sound absorbing materials on the outer surface of the Grillbot as well as around the motors to reduce the noise Since the materials are new changes we are implementing on the product they do not change any specific metric The only major change is the length of the shafts The specification sheet can be found in Appendix AG 53 Functional Redesign Avenue Selecting various functional improvements to the Grillbot allowed us to narrow down and add new specifications to the specification sheet Appx AG The first change we want to make to improve cleaning is to increase the weight Therefore we chose a higher target value for the mass We also increased the cleaning time from 30 minutes to 60 minutes and we changed the
17. The exploded view is a very helpful tool for visualizing the physical arrangements of interior and exterior parts Appx P Understanding a product solely based on its drawing views can be very confusing especially when the product has over 20 parts The other purpose of the exploded view is to use it as a guide for reassembly 37 The many radial components as well as the linear components made our product challenging to present in an exploded view For example screws attach the shell body assembly in the z direction but a 180 degree radial distance separates them To show the locations of parts we found it best to show the main axes on a 3 D image of the Grillbot instead of in the exploded views To elucidate the part alignment we included a subassembly of the electronics unit The subassembly includes the main circuit board and the sub circuit which are connected by an 8 pin cable It was easier to show the internal circuitry as a subassembly because in the main assembly we wanted to highlight the position of the motors However the motors are soldered directly to the main circuit board and not removable Therefore the position of the electronics was necessarily in the middle of the lower shell making the components difficult to see The exploded view the subassembly of the sub circuit and the axial denotations are located in Appendix P Actual Function Structure In the actual function structure we recreated the functional
18. a IS ud 5 0 9 O 6 9 0 D 0 Uu O tb u 9 1 a o T 0 0 uU D cil eb o g Does not damage uy EZ je grill t purchase cost ood function for the price ong lasting life of components 0 O O ro O 6 min O O V 21 o 5 o lo T o Ic S 3 0 5 O 3 3 m c D 2 jad o 0 y O C 0 500 2 35 241 130 4 60 75 6001 2 25 241 60 1 40 40 Our Grillbot Target Values 114 What T gets Tar ric Met Appendix I Specification sheet Demand Wish Project Design specification sheet for Grillbot Responsibility Test Verification 2 15 15 Volume 241 164 inches 3 VOLI VIUEN e meeting Drawing 2 15 15 mEMM Rotation Rate of Wheels Verily with output torque of motor 2 15 15 EE NC Mass gt 4 lb Measure Weight 2 15 15 a Strength of Wire Brushes gt 600 MPa Test through Tensile Strength Test Material 2 15 15 Operating Noise lt 40 dB All Measure Sound with sound level meter 2 15 15 Beeping after shut down lt 40 dB All 0 4 level meter Cost 2 15 15 D D S Cost of Product 60 Perform Cost Assessment Schedule Measure time required to O l clean the grill with stop 2 15 15 Time it takes to clean the grill 10 to 30 min All RUN 2 15 15 Time to wash the brushes lt 10 min Measure time required to clean brushes with stop watc
19. cos 45 i sin 45 j cos 45 i sin 45 j cos 45 i sin 45 j X X cos 45 i sin 45 j cos 45 i sin 45 j cos 45 i sin 45 j cos 45 i sin 45 j Appendix N Product Disassembly Plan Hand Hand Hand Screwdriver Screwdriver Hand Hand Hand Screwdriver Hand Hand Screwdriver Hand Screwdriver Hand Hand Screwdriver Hand Screwdriver Hand Screwdriver Hand Screwdriver Hand Screwdriver Hand Screwdriver Hand Screwdriver Hand Hand screw drive Screwdriver Hand Hand Remove Remove Remove Unscrew Unscrew Remove Remove Remove Unscrew Remove Remove Unscrew Pull out Unscrew Pull out Remove Unscrew Remove Unscrew Remove Unscrew Remove Unscrew Remove Unscrew Remove Unscrew Remove Unscrew Remove Remove Unscrew Remove Remove 120 Brush wheel 1 Brush wheel 2 Brush wheel 3 Top shell screw Lower shell screws Lower shell Top shell Handle Sub circuit screws Sub circuit Rubber power button cover Power cord screw Power adapter Main circuit screws Battery Battery cushion pads Shaft 1 screws Shaft 1 Shaft 2 screws Shaft 2 Shaft 3 screws Shaft 3 Motor 1 screws Motor 1 Motor 2 screws Motor 2 Motor 3 screws Motor 3 Bottom pad screws Pads Thermocouple epoxy Label screw Label washer Label O CON DWM Sh 0 HL 121 Bill of Materials Team The Grill Master Date 3 9 2015 DFM Cost Analysis Data Part Part Name Quantity Function Mass 2 Finish Manufa
20. terceras personas en relaci n con la obra y en particular de reclamaciones relativas a los derechos de propiedad intelectual sobre ella 5 Deberes del autor El autor se compromete a 2 i a 7 En el supuesto de que el autor opte por el acceso restringido este apartado quedar a redactado en los siguientes t rminos c Comunicarla y ponerla a disposici n del p blico a trav s de un archivo institucional accesible de modo restringido en los t rminos previstos en el Reglamento del Repositorio Institucional En el supuesto de que el autor opte por el acceso restringido este apartado quedar a eliminado a Garantizar que el compromiso que adquiere mediante el presente escrito no infringe ningun derecho de terceros ya sean de propiedad industrial intelectual o cualquier otro b Garantizar que el contenido de las obras no atenta contra los derechos al honor a la intimidad y a la imagen de terceros c Asumir toda reclamaci n o responsabilidad incluyendo las indemnizaciones por da os que pudieran ejercitarse contra la Universidad por terceros que vieran infringidos sus derechos e intereses a causa de la cesi n d Asumir la responsabilidad en el caso de que las instituciones fueran condenadas por infracci n de derechos derivada de las obras objeto de la cesi n 62 Fines y funcionamiento del Repositorio Institucional La obra se pondr a disposici n de los usuarios para que hagan de ella un uso justo y respetu
21. the compressor that would be attached to the battery Our battery output is approximately 3W with a very low impedance Because our motors require an approximate output of 0 5W each we only have about 1W of power to use Finally we want the output velocity to be as high as possible From online specs we found that many pressure washers have velocity steams of 15 m s using this as our starting value we found the flow rate is much too high for practical distribution purposes and reduced the velocity instead to 10 m s which will still create a significant amount of applied force on the grille debris From these limitations we developed a design that would be able to modulate the output flow such that we can send water out of 10 nozzles with a velocity of 10m s for 1 second every 30 seconds By using a liquid jet steam the Grillbot can reach spaces in between the grille bars that are too deep for realistic brush penetration Additionally the inclusion of water will help to increase the cleaning efficacy by means of increasing lubrication The assumption e Power is conserved e Head pressure is negligible and the velocity of the water in the pressure tank is zero Wecan build a tank that supports 50 kPa without exploding e We can divide distribute the pressure buildup across 30 s charging time e The air pressure on top of the water creates an equivalent internal pressure in the water 183 e The battery can consistently output the required p
22. 094 869 Filed Mar 31 2005 Prior Publication Data US 2005 0186343 A1 Aug 25 2005 Related U S Application Data Division of application No 10 371 198 filed on Feb 20 2003 now Pat No 6 906 295 Int Cl C23C 16 00 2006 01 DEA UN een 427 255 15 Field of Classification Search 427 250 427 255 7 248 1 See application file for complete search history References Cited U S PATENT DOCUMENTS 4 436 830 A 3 1984 Andreev et al 4 554 201 A 11 1985 Andreev et al 5 262 241 A 11 1993 Huggins 5 403 882 A 4 1995 Huggins 5 447 803 A 9 1995 Nagaoka et al 5 503 912 A 4 1996 Setoyama et al 5 525 420 A 6 1996 Kaufmann 500 54 75 73 T 62 51 52 58 56 US008844087B2 US 8 844 087 B2 Sep 30 2014 10 Patent No 45 Date of Patent 2013 01 A46B 15 0081 2013 01 A46B 15 0055 2013 01 A46B 5 0095 2013 01 AL CARA 15 111 15 236 01 15 105 58 Field of Classification Search CPC A47L 13 34 A47L 13 06 A47L 13 12 A47L 13 022 A47L 17 06 A46B 2200 3093 A46B 5 026 A46B 15 0081 USPE AS 15 111 236 01 See application file for complete search history 56 References Cited U S PATENT DOCUMENTS 4 091 579 A 5 1978 Giangiulio 4365380 A 12 1982 Fassler 5 643 403 A 7 1997 Poole etal mom 156 762 6 966 094 Bl 11 2005 Rigakos 7 818 843 B2 10 2010 Kinskey et al 8 225 451 B2 7 2012 Weinberger et al 15 111 200
23. 1 Product Introduction Background Literature Customer Needs Analysis 02 02 15 09 02 15 100 Customer Interviews House of Quality Specifications Sheet Activity Diagram Start Date Target Date To do List Gantt Chart Black Box Model 2 18 15 2 22 15 H hesi F i ypothesized Function 2 18 15 2 22 15 Model Cross Sectional Sketches Product Disassembly Bill of Materials Exploded Views Actual Function Structure Comparison Function Structure Summarize Entire Reverse 3 2 15 3 6 15 Engineering Update Specification h Sheet and problem 3 2 15 3 6 15 100 statement hase 2 To do List Gantt Chart Select Adaptive Avenues Brainstorming Mind Maps 6 3 5 Design Ch 65580 ange Concept 3 16 15 3 22 15 Generation F ional Re desi unctiona e design 3 23 15 3 28 15 Concept Variants ial Design Shif ndustria esign 5 ift 3 23 15 3 29 15 100 Concept Variants Pugh Chart Order of Magnitude hase 3 To do List Gantt Chart Develop Experimental 4 6 15 100 Model Experimentation Back of the Envelope FMEA Design for Assembly Design for Environment Preliminary Drawings 190 Appendix AJ Brush Prototypes Figure AJ 1 Experimental Prototypes Appendix AJ 2 Prototype with the weight 191 Appendix AK Pictures of Experimental Model 192 Brush Brush Motor Adapter Grill rod mount Brush mount Sliding plate Brush adapter 193
24. 1s powered on or off 35 Product Disassembly Plan After completing all of our predictive models we began to disassemble our product following a systematic procedure First we produced the disassembly plan for the Grillbot by documenting the steps we followed during the teardown Appx N Then we laid out all the different components and parts with their corresponding screws beside them and carried out the exploded view Last of all we used all the information gathered to create the bill of materials Appx O We used a few tools that were easily available to us in the J lab and were all reversible processes Those tools are mentioned in the disassembly plan as well as the direction of 66 99 is the vector for the x direction and J for the y direction Unfortunately 66599 1 disassembly where we broke an unessential doghouse clip from the top shell because the plastic was not flexible First we removed the top and bottom screws to get the two main body shells apart Once the base assembly was separated the internal structure was revealed The inside of our product was similar to what we had expected in our predictive cross sectional sketch Appx L Components that attach to the bottom shell are the three motors the battery pack the thermocouple and the main circuit Components that were attached to the top shell are the LCD sub circuit and the power cord Also they were both connected to the main circuit Next we r
25. 20 101 Sohn Ladens ame E D 1004 ue vour 2111110 experience level 1 2 3 Y 5 P Appearance 1 2 3 4 gt Comment Noise i 2 3 4 5 Comments Effectiveness 1 2 5 4 5 Lommecnt Easy to hold 1 2 8 4 5 comments Easv to clean the GrillBot 1 2 G 4 5 Lomment bt B Easv to operate figure out Comments Value 130 1 iQ 3 4 5 Lommenis d Overall ratine 1 2 6 4 5 at do vou like about ihe Does v Jeanwa Lei WE What do vou NOT like about the GrillBot The price What would vou change Dadivides ates 7 Carte Pa be longer sr hing dJ Would vou buy it Whv whv not A Na Because TS litte Ame c faa wy geit 11 not wnat Would vou nav tor y 35 00 7 f Me 2 102 Name Hamas Baa 11000 dae vour eruine experience level i z 3 4 Appearance i 2 3 A gt Lomments Noise l 2 3 4 5 Comments Effectiveness 1 2 3 O 5 Comments Easy to hold x FF Comments Easv to clean the GrillBot 1 2 3 4 5 Lomments Easv to operate figure out 1 2 3 4 6 Commenis Value 130 E 0 MN 4 3 Comments 1 Overall rating I 2 3 4 5 Whar do vou i ke about the UriliBot Rew cleane gait What do vou NOT like about the Grill Bot Prvi e What would vou change Lowe poce Would you buy it Why whv not We Jue ao X gn 1 ques If not what wouia you pav for 1
26. Classification Search None See application file for complete search history 28 33 54 75 73 21 22 65 30 Jun 16 2011 51 52 58 Appendix C Rugged Grill Brush 92 Appendix D Activity Diagram poe z Read Power Set Remove Wipe Down Replace Dishwash Remove Grillbot Brushes Brushes Brushes Place on Charger gt Put on Clean Brushes 93 Appendix E Customer Interview Sheet Name Bad Good Rate your grilling experience level 1 2 3 4 5 Appearance 1 2 3 4 5 Comments Noise 1 2 3 4 5 Comments Effectiveness 1 2 3 4 5 Comments Easy to hold 1 2 3 4 5 Comments Easy to clean the Grillbot 1 2 3 4 5 Comments Easy to operate figure out 1 2 3 4 5 Comments Value 130 1 2 3 4 5 Comments Overall rating 1 2 3 4 5 What do you like about the Grillbot What do you NOT like about the Grillbot What would you change Would you buy it Why why not If not what would you pay for it 94 Interview responses Name Sut E Baa tooa Zare vour grunne experience ievei i 7 3 Lo 5 a Z Appearance 1 2 3 Comments 6 ver EX n Te D er Noise 1 2 3 4 5 t Orientis c ud Wy Coces ve GUA Shet IT PT Effectiveness 1 2 3 4 5 3 LU TUE es npue LEFT Easv to hold i 2 3 4 5 Comments Qow D 45 9 UnA E A Un ADLE OM lo P Easy to clean the GrillBot 2 3 4 5 Co
27. For each of those ratings the customer adds additional comments Below that are a few more questions that ask what they liked disliked and what they would change Finally we asked how much they would pay for the Grillbot The last question will come into use when we decide how much less expensive we should make the Grillbot as we believe cost savings would be a good thing to improve The interview responses are also shown in Appendix E We set up three grills one charcoal one propane gas and one charcoal that had not been cleaned in about a year The very dirty grill was not lit up but we did light and cook hamburger patties on the other charcoal and gas grills The three types of grill surfaces would allow the customers to imagine how the Grillbot would clean their own grill no matter the type Additionally the customers could see the effects of cleaning both hot and cold grills Before cleaning we asked each customer to hold take apart and reassemble the product They were given only basic instructions like how to turn it on and off After cooking the burgers and dirtying the grill surfaces we waited until each grill was under 250 degrees F as instructed in the manual Then each customer placed the Grillbot on the grill noting the ease or difficulty with holding and placing the Grillbot and selecting a cleaning time We had about three customers interact with it 28 on each grill After cleaning for 10 minutes the customers took note of
28. Hoekens linkage to convert rotational motion to approximate straight line motion of a point with a four bar linkage Appx AA We think using a slider could be good for our product because it will clean the same surface repeatedly which could get rid of residue on the grill better Due to the small space between the gratings of the grill using a Slider is not a good idea Linkages are hard to adopt because they need a larger area Our target volume is 241 cubic inches Appx H and we want to maintain it As a result a three wheeled robot is the most feasible idea To regulate friction we considered using electric sensitive material adding a potentiometer using different types of brush materials or brush patterns and increasing the weight of device If we use electric sensitive material it would adjust how hard the bristle works depending on the amount of voltage As the bristle gets stiffer the friction caused by the brush will get larger thereby cleaning better There are many types of grills For a coated grill 1t needs to be cleaned carefully otherwise the bristles will peel the coating of grill For an uncoated grill we can use sturdy bristles Therefore depending on the type of grill the users can adjust the hardness of the bristle It has a potential for many users to clean different types of grills We could use a potentiometer to change the angle of various parts For instance our team could use it to change the angle of the bris
29. No 5839454 We believe this product will be useful for designing additional methods to increase the effectiveness of the Grillbot The patent describes the useful hydrophobic properties of soap and methods for dispersing the cleaning fluid For a future design we are interested in finding methods other than manual work to assist in deep cleaning the grill surface The patent covers are shown in Appendix B To summarize our findings we have discovered that our target demographic is middle aged head of household males with disposable incomes The product aims to make grill cleaning easier and more effective The main features of the product that detract from customer satisfaction are its loudness ineffectiveness and short life span Using this information we have constructed our customer interviews to address these points as well as provide an open forum for new criticism The Grillbot is one of a kind when it comes to robotic grill cleaners Therefore there are no direct competitors but there are other options when it comes to cleaning a grill In the end cleaning a grill is a relatively easy task and most people would opt to simply use a brush For the few who find it too strenuous to manually clean a grill with an ordinary grill brush the only other option is the Grillbot or a better more innovative grill cleaning brush The Grillbot s competitor comes in the form of the most innovative and toughest grill brush in the world the Rugged
30. attainable to greatest are as follows noise reducing material improved brush bristle material improved handle increased motor power addition of weight Update Specification Sheet After going through the redesign process we evaluated the previously completed specification sheet Appx I to see if there were any necessary updates to be made The first change we made was the mass section After weighing the components and getting a combined weight of 3 35lbs we decided to lower our minimum allowable weight to 3 5lbs After disassembling our product we know the exact number of parts of the Grillbot Therefore we changed the maximum allowable number of components We used a phone application called dB to measure the noise rather than using a sound level meter We also compared the result we got from the phone application to the noise made by similar products to verify the values we got Lastly we used the motor torque and power to calculate the rotation rate of the wheels with the following equation Power Hp speed rpm 41 It is important to update the specification sheet because we know the true values and can work on the redesign avenues better The updated specification sheet is located in Appendix T Problem Statement After going through the reverse engineering process we came up with several redesign avenues The most significant of the redesign solutions is noise level reduction All of the
31. complaints about the handle for the product Appx G The current handle design has small lipped edges that make the Grillbot difficult to grasp We aim to provide a more efficient handle while still maintaining the low height 40 clearance of the product A simple way to do this is to smooth out the edges to be more comfortable for the user However if possible the ideal redesign would be to create a novel arched handle that allows the user to grasp it fully In the next phase of this project we will explore whether or not this type of handle is feasible for compliance with our design specifications When it comes to importance of each proposed redesign we considered the most important aspect to be the key functionality of the product how well it cleans the grill Therefore the most important redesign avenues are to increase weight and motor power We considered the customer s needs to be second highest in importance so we placed the noise reducing material and the better handle next in importance Finally we consider the new brush bristles to be least important since it is simply a redesign based on our opinion and experience with the product The redesign avenues listed in order of greatest amount of innovation to least amount of innovation are as follows noise reducing material improved brush bristle material increased motor power improved handle addition of weight The redesign avenues listed in order of attainability from least
32. further between the grill edges When compared to the current design I think that the copper wire should be shaped more like bristles like in the current design Customer 3 I think this is an excellent prototype The fact that the bristles can touch the surface of a grill Also the facts that the bristles are different lengths allow the user an Customer I like prototype 1 for the grill better because the designs seems to clean more than the current design Prototype cleans in between the wires in the grill instead of easy way to fit the cleaner in the desired orientation Lastly I love the color It looks fun to use Customer 4 I like the idea of the long and short bristles It will provide the same cleaning potential as the current product and also provide extra cleaning in the grooves The longer bristles are a bad idea They will not provide enough cleaning on the top of the grill where the food will be touching mostly Customer 5 Prototype 2 is good because the longer bristle cleans the side of the grill and the short bristle cleans the top party It is more efficient because it takes care both top and the side 170 Appendix AF Order of Magnitude Calculation MANNE FORCE dmmshae why this ull maoe cleaning F di M mass of Gallbo mM BKB Me kure coeficent fickan M 5 N MQ SEG Omjs SON F AN 05 S0N 25N Assume Nye Sta Na m m 9 10 kg 10m s 100 N Fr
33. housing The possible causes of a stator of a motor are physical damage contamination corrosion high temperature voltage imbalance broken supports and rewind Stator failures often occur due to the rewind burnout of the windings As a result the motor could shut down or work inefficiently Stall failure could happen due to fatigue and this would reduce the motor s efficiency The third failure come loose can be caused by wear tear poor assembly or faulty equipment For example if the motor s shaft were too small then it would not fit in the brush motor shaft and would fail to connect the brush and the motor Housing could be the last possible failure mode we came up with It can be caused by improper installation physical damage corrosion and material buildup and the failure will result in motor shut down or inefficiencies For example a soft foot could lead to the motor shaft bending and broken Material buildup can increase its operating temperature of the motor and lead to damage on other parts of the motor 63 such as bearings Next the failure modes of the brush motor shaft are wearing and fracture Wear can occur when the product is overweight or when it is overused Fracture can occur by abusing or misusing the component Both failures would lead to failure to connect the brush and the motor The brush wheel is the next component we will discuss and its failure modes are wear and oxidation Abusing the components o
34. how clean the grill became and turned the Grillbot back on for an additional 10 minutes if it needed more cleaning Throughout this process the customers talked amongst themselves discussing some of the positives and negatives about the product Customer Interview Results The general consensus was that it was too expensive and noisy but did clean better than expected For many the Grillbot seemed like an unnecessary expense because with a 10 or less brush and a few minutes a person could accomplish the same level of cleanliness The sounds the machine made while working underneath the grill covers inspired what became a running joke that it sounded like a Tasmanian devil or like we were grilling a live squirrel We did conduct the customer interviews in the evening and at night so some of the customers could have interpreted the higher noise level as more bothersome because of the surrounding neighbors Though all of the customers would not have paid the 130 manufacturer s suggested retail price those who rated their grilling experience higher also rated their suggested price higher We show this in Appendix F This might mean that more experienced grillers appreciate the product more and therefore give it a higher value After all most people found that it did do an acceptable job of cleaning the grill though a few were tempted to do a once over cleaning with a hand brush to finish off the job Looking at the summary of the ratings each cu
35. model Appx Q using the real life components and design of the Grillbot The diagram works in a similar fashion to the hypothesized version and is as follows First the hand comes in and out as a material input to operate the power button Those power on off and time setting signals move through a sub circuit located near the power button before arriving at the main circuit The main circuit sends electrical energy and information signals to either the motors or the sub circuit From the sub circuit electrical energy powers the speaker which beeps and sends the power on off status and temperature overheating alarm as information outputs Alternately from the sub circuit electrical energy powers the LCD which displays the signals of battery and cleaning time remaining as information to the user From the main circuit electrical energy flows through motor wires which transmit the energy to each motor The motors convert electrical energy into rotational mechanical energy albeit with waste thermal and acoustic energy The brushes take the rotational mechanical energy and convert it to translational mechanical energy moving the Grillbot over the erill surface and cleaning it The brush wheels take a dirty grill as material input and send out a cleaner grill and food matter as the material output 38 Comparison The hypothesized and actual functional structures are very similar meaning that our prediction was accurate The main difference betw
36. of grill Customer 1 likes prototype 1 because he thinks it will clean the edges of the grill Customer 4 mentioned that he does not like prototype 1 because he thinks it would not clean the top of the grill As a result we will try to manufacture the brushes in the future with our designs and test to compare the results of the current brushes and prototypes 52 Order of Magnitude After we had generated concepts we wanted to see how they would improve the cleaning process mathematically The calculation allows us to see if our concepts would be feasible Concept variant 1 will increase the friction force applied to grime by a factor of 2 The resulting impact velocity from bending will also double Overall we can expect more than double the effective forcing on debris by adding 5 kg For concept variant 2 the total cleaning area of the current brush is 220mm and the total cleaning area of the new one is 8400mm which is 3 76 times larger Concept variant 3 uses soapy water to cut the grease and food particles making for easy removal The soap contains detergent molecules that bind to both polar and non polar molecules allowing them to emulsify and wash away For concept variant 4 the total grill area being cleaned with the current brush is 1 26m and 2 51m with the target motor The target motor can clean an extra area of 1 25m because the cleaning time generated by the target motor is two times longer than the current motor
37. purchased container or an udessated stesape recep The imvenkon allows an individual io determine the of detergent io be asked wath provisions 10 Operate Ihe deteriora Lester onb upon demand preventa operation of ihe dishwasher il an insulliciem arbol La deierpeni s available An alernative tanbodinent allows posan of a slorage heaealh the clishwasher chamber wiih provisions All Lae container 18 Claims 12 Drawing Sheets United States Patent a Matz AUTOMATIC DEFERGENT DISPENSER inventor Warren Y Mate 13882 ELS Hwy Juno Beach Fla 13408 Appl No 818 605 Filed Mar 14 1997 Into ATL 15 44 ES Ch 22222 LANET FE 134 58 D 134799 3 13410 1 1 1337113 Poli af Search ou 13450 D 37 ER 134 58 D 91 2 URAL HA 083218 17 Ro Sea BA References Clted ELS PATENT PHOCUMENTS BATHE Pax 2224 DEE BR AA MA 2207 300 597 Au m 87 E 76 21i 2 31 523 38 56 US007462375B2 10 Patent No US 7 462 375 B2 45 Date of Patent Dec 9 2008 5 562 991 A 101996 Tannenbaum 5 700 551 A 12 1997 Kukino et al Continued FOREIGN PATENT DOCUMENTS EP 0872575 10 1998 Continued OTHER PUBLICATIONS Luo et al Tribological investigation of Ti AICrN and TiAIN CrN coatings grown by combined stcered arc unbalanced magnetron deposition Vacuum 53 1999 p 123 126 Continued Primary Examiner Timothy H Meeks
38. result of a specific part or function of the product but simply an unavoidable outcome of the product producing adequate force for cleaning Therefore in order to reduce sound we decided our only option for redesign was to add noise absorbing material to the product In doing so we could also add weight to the Grillbot which leads us to our next redesign avenue Some possible noise absorbing materials that we researched are listed in Appendix S One issue we noticed with the Grillbot during the performing stages of the product was that for certain grills it did not have enough force to clean the grooves and sides of the grill rack In order to increase the cleaning power of the brushes we would need to add weight to the Grillbot Adding weight would create a greater downward force of the brushes but also creates greater resistance against the lateral motion of the brushes Therefore in order to avoid the possibility of the brushes locking up we also need to increase the motors output power which would also increase its cleaning power Along the same lines we also noticed how quickly the brushes became dirty and how difficult 1t was to clean them In order to eliminate this issue we simply proposed a different material for the brush bristles By using a more durable and stick resistant material we could increase the lifetime of the brushes and reduce the amount of cleaning necessary The last avenue for redesign is based on our customers
39. the function component matrix Further design techniques will be provided in Phase II Conceptual Engineering Design Black Box Model Our black box model of the Grillbot represents the overall function of the device using energy material and information as categorical inputs and outputs Appx J The primary system function of our black box is to remove sediment from a dirty grill The boundary of the black box or primary function of the Grillbot is defined to divide the action of the Grillbot during cyclic operation and the beginning and finishing processes that directly involve the user The energy inputs supplied to the machine are electrical energy through the lithium ion battery pack and thermal energy of the warm grill One of the material inputs to the black box is 33 the hand that positions and selects the running cycle Another material input is the grilling unit to be cleaned The informational inputs to the system are the run time setting fed by a control button actuated by the user the battery sensor which indicates with LED lighting the percentage of power left in the battery and the temperature monitor that alerts the user if the heat from the grill exceeds the material capabilities During use of the primary function the Grillbot outputs thermal energy expended by the friction between the brush wheels and the grill acoustic energy by operational noise and collisions with the top grill lid rotational kinetic energy thro
40. the weight Generally the development risk of sourcing parts is difficult and the durability is closely tied because more complex systems are usually harder to procure and less reliable Because of its higher weight modifying the brushes makes the product easier to use while having to add fluid for the water dispenser or water jet makes them less easy to use With modifying the brush in terms of datum purchasing cost development risk and durability prove to be better than the other variants because of its simplicity Though simple the 54 better brushes also reduce their relative cleaning time while increasing their cleaning ability and not affecting their ease of use compared with the stock design While looking at the water dispenser as the datum point we found that 1 performed worse than all the other variants except the water jet Dispensing water added cost development risk and unreliability compared with increasing the weight modifying the brush or increasing cleaning time The water jet proves to be more expensive and more unreliable relative to the other options However it is ranked by far the best cleaning performer because it adds a high pressure water jet to the existing Grillbot easily blowing away stuck food particles However due to its complex setup which involves filling the Grillbot with a cleaning fluid and then having to clean up wet coals and ashes beneath the grate the water jet is less easy to use and requir
41. unlikely to buy this product It is inefficient from a time and cost perspective So the amount of physical work it takes to scrub a grill with a normal brush is worth it to some consumers Activity Diagram To understand how the customer uses the product we had to record the procedural steps First the product has to be fully charged to be useful If it is not fully charged the machine has a beeping mechanism to let the consumer know that it needs to be charged Next the device is set on the main grill and the time setting button is pressed once for 10 minutes twice for 20 minutes or three times for thirty minutes The lid is then closed so that the Grillbot does not fall off If the lid were to be left open the Grillbot would roll off the side After the cycle has been run the user then removes the Grillbot either to clean it or to store it If the user were to clean the Grillbot they would need to remove the brushes by pressing the release button and wash them in a washing machine ideally If a washing machine is not available it will be difficult to clean the tightly spaced metal bristles This activity analysis is helpful for several reasons First we know that the grill must have a lid Therefore any permanent set grills 1 e campground grill park grill or neighborhood grill are excluded from product use This narrows our market down to personal grill users In addition we discovered that the consumer would be unsatisfied if they
42. used statistical tools to acquire the mean response main effect of each control and control interactions which we then used to plot regression models for the two responses What these 3 D plots demonstrate is that that maximum performance is predicted to occur when both concept variants are increased even though the results contest each other s main effect contribution from each variable The depth plot demonstrates the Bristle length to be the most important variable to performance whereas the surface area removal plot suggests weight to have the most effect Regression Models are shown in Appx AN Failure Modes and Effects Analysis After conducting experiments and determining the design modification for the product we built the Failure Modes and Effects Analysis FMEA for the original product and the redesigned product It can be found in Appendix AO We revisited the bill of materials Appx O in order to think about the components that could fail We wanted to focus on making adjustments to the components with Risk Priority Number RPN higher than 100 After we made adjustments we 62 input the data under improved situation columns in FMEA table We will target specific areas of possible failure modes and evaluate their level of impact on the functionality of the product by doing this Building FMEA will be beneficial for us to redesign our product to be more complete Original product We listed some components that could fa
43. water jet will lift up food particles Also this method just needs water therefore the customer does not need to buy detergent The fifth analogy is ultrasonic glasses cleaner Ultrasonic glasses cleaner uses high frequency sound waves to remove many types of contaminants from parts immersed in aqueous 46 media If our device has a big bath that could immerse grills in high frequency sound waves between 20 80 kHz Ultrasonic n d will remove dirt on the grill Morphological Matrix The morphological matrix Appx Z helps to organize and categorize many different ways of performing specific functions First we came up with sub functions that affect cleaning quality from our actual functional diagram from Phase I The components that have to do with cleaning are the motor the brush motor shaft and the brush wheel We first listed their sub functions converting electrical energy EE to mechanical energy ME converting rotational mechanical energy RME to translational mechanical energy TME transmitting rotational mechanical energy and regulating friction In order to advance the cleaning process we considered adding other components to complete extra tasks such as converting EE to thermal energy ThE and importing fluid We investigated these functions in terms of EE ME ThE acoustic energy and fluid principles To convert EE to ME we came up with using an AC motor and a DC motor with different speeds or durations
44. with thermal heat transfer and it has a large user demographic The electro mechanical system as well as the thermal dissipation methods embedded in the Grillbot provides us ample Opportunity to perform analytical and experimental modeling on the product Additionally because the product was only released in January of 2014 it is only about a year old The immaturity of the product is advantageous for us to find critical design issues that were overlooked during development Finally I have a genuine interest in learning how this product functions and engineering solutions that will make it a better machine The purpose of the Grillbot is to remove the particle buildup from a heated grill without the need for user effort The machine does work by means of three separate electric induction motors that impart torque to shafts with embedded wire bristles The motors rotate based on an algorithm programmed into the controller that randomizes alternating motion The rotating brushes are removable and available for purchase with either steel or copper bristles The Grillbot works on three timed settings 10 minutes 20 minutes and 30 minutes These three settings are intended to accommodate all levels of grime removal The power from the Grillbot comes from an internal battery source so that it can function portably The Grillbot can nominally run for five 30 minute cycles on one battery charge The battery is then recharged from an AC power adapter that is
45. y el cambio de concepto de varianza Con estos datos podemos recomendar de forma concluyente la implementaci n de alargamiento de cerdas y el aumento de peso para un redise o sencillo barato y eficaz Despu s de realizar AMFE encontramos los distintos modos de fracaso y maneras de disminuir las posibilidades de que suceda Al considerar DFM DFA y DFE se identificaron otras formas de mejorar el Grillbot tales como una mejor fabricaci n montaje y uso Por ltimo sobre la base de nuestros resultados experimentales se construy un prototipo final Este prototipo Alfa funcional representa el cuerpo de un semestre de trabajo que pusimos en el Grillbot 18 INDEX PHASE I TASK CLARIFICATION AND REVERSE ENGINEERING A Gantt Chart and TO DO LISI ae aaia Literature REVIEW pc en eese DIM i a SEO Customer Needs Analvsl ansehen House or Quality HOO FASO ESED ROO Specification Shetland Black Box Mode Tc Predictive Cross Sectional Sketch 6 0m En nal Hypothesized Functional Structure Product Disassembly Plan al A cet FE S EXDIOGEE N pem Actual Function StrUelure 2er I ee Om 02 I ESI A sd SDRC Iunc aon component MATI iiie eese etes na s mmarization of Reverse Engineering eee eer ee noia Aeon oos eos UU vus
46. 008 200 Appendix 2 Minimize part count by incorporationg multiple functions Modularize multiple parts into sin gle sub assemblies into single parts b Don t Do Design open enclosures to permit assembly in open Parts should easily indicate orientation for insertion Space not in confined spaces Never bury important c d Y Figure 14 3 Design for assembly system guidelines 201 Appendix AQ Design for Manufacturing Guidelines Telenkom et al 2008 Don t Do Use ribs instead Do t gt 4mm No draft 0 065 s t lt 0 5 7 Add thickness for draft Minimize section thickness cooling time is proportional to the square of the thickness of the part s and reducing the cooling time directly reduces costs Always provide a draft angle for easier mold b removal Don t Do riba trip Ze 31 min voids Sink marks Keep rib thickness less than 60 of the part thickness to prevent voids and sinks Avoid sharp corners they produce stress concentrations and obstruct material flow c Don t Don t Potential sink marks and voids P Stepped thickness transition Do Do Attach bosses to walls with ribs ao Gusset free standing ribs Keep section thickness uniform around bosses Make all transitions smooth and avoid changes in thickness when possible f
47. 2 0040686 A1 4 2002 Willinger et al cited by examiner Primary Examiner Shay Karls 74 Attorney Agent or Firm Deron A Cook Robert E McDonald Daniel A Sherwin 57 ABSTRACT A wire brush may have wire type tufts extending from a head and may have a handle with only one finger separator And or a wire brush may have a manually detachable scraper that has a pair of tabs received ina pair of grooves formed on the brush body 18 Claims 9 Drawing Sheets United States Patent Marsden et al 54 WIRE BRUSH 75 Inventors Andrew K Marsden Avon OH US Michael Lambertson Jr Aurora OH US Dennis P De Renzo Jr Concord Township OH US The Sherwin Williams Company Cleveland OH US 73 Assignee Notice Subject to any disclaimer the term of this patent is extended or adjusted under 35 U S C 154 b by 120 days 21 Appl No 13 168 001 22 Filed Jun 24 2011 65 Prior Publication Data US 2012 0096659 1 Apr 26 2012 Related U S Application Data 60 Provisional application No 61 358 773 filed on Jun 25 2010 51 A47L 13 06 2006 01 A46B 5 02 2006 01 A46B 17 08 2006 01 A46B 15 00 2006 01 446B 5 00 2006 01 52 A46B 17 08 2013 01 446B 2200 3093 2013 01 A46B 5 026 2013 01 446B 5 02 89 12 INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY PCT 19 World Intellectual Property AARAU AL
48. 25m extra area 176 HS PRESSURE JET ne 7 A N IN INS JETS SHELL 4 ASSUME You 45m s The Vekaly Of a wosher 2 BECAUSE OF WATER SOLASE LIMITATIONS ITA 1L dure of a seda bafe 000cm do 4e Sides 1L ue can add extra voure we will need to pde ud h moate He flow such thet sis 40 mnutes 3 ASSUME 40 ahed hoes Rar 27 mn 4 ASSUME a de every Amie 10 wees Im aT TT u d 3 ge v SE SE owe l oo2ma 89 000 m s ooma He We _ M gt ZT 50 000 S gt 10s so fy exh of e Therefore total hme ys Sms fy AL seand sfay time 40 Qcles e an dean mb TAS IS NOT ENOUGH 177 Qc 60 ydes Every 30s 20 Ydes s cucle t kets rn the Code fo 4 Second even 30s With a J veloaky of Aomls VELOCITY IN A PESSE CHAMBER 0 The pressure required te face the lud ok 495 2 89 gtantat un eoe ole IN an on a ea of Tim IS om g related to Bemodi s eavation 0 o ga AG tt phis Assume he density Of water 4 p IS for 100068 rm2 2 1000 talm 7 9 la ms 50 000 3 2 5 By TT Therefore the peak power requred Lor FQ 50 000 x 2 Sw 4 20 008 adyust 4o 10 6 Tora energy P Sw
49. 2s 103 Fue wart to bud w the oepootance Gmiinualky in the Storage tank ey 305 q Bl la W 20s a 178 Because hadraulic pops are vom ex pens we we will Use BRA air o MPSD do p gt 6 ta tur cy lindor ES 1 ompressor 1 30 006 mini 5 the air compres SO EL ve slate the 0 55 e p a u oF 1S unrealistic o ba ery ran pe na ot v load e O 163 te 7 gina d as rise time of tho net 1 2 0 8 7 on no a much move ce e 3 Z Compre cSSoP sauf ht Orem MoTo CS VQ 7 70 mk m x s P iiv roma l AIN D Tha eCove 3 GUV ey dr u S about s d J 1 5 maximum Our battery can 6 Mac o 179 _ sw Enck TET Velas 10 m s f ZO N APPLIED qe me ines M 4 Lome most vlecular this bindim free betten paridas and pla s rfuce He Therefore in addition lo tha Siwas of tu brush spidles tle jet will meke Cleanica added poem u de much Pant effective 58 6 D Mem A he CoVERING E eles PLessuRe 2 VESSEL poc 6 VIEW PR TOP View wJ 1 E soi HEE D T yoLES KJ Im En pa DISENGACEN O y b 180 Description of Order of Magnitude Calculation The first
50. 8 123 On Off switch Subcircuit screw 1 3 Subcircuit screw 4 e Subcircuit LCD circuit Subcircuit screw 2 LCD display Subcircuit screw 3 p Battery connector cable Power adapter port Main circuit Subcircuit cable 8 in 21 cm ruler for scale d Main circuit screw 1 a Main circuit screw 4 4 v i Main circuit screw 3 H LI 7 gt i S SS Main circuit screw 2 SS N Motor 1 N M a D Motor 2 Motor 3 Thermocouple Scale 1 4 124 125 Oty gril 81 Qeaner gril to TME TME 5 Waste THE Waste Acoustic E Brush 2 aner 0 Convert RME to TME TME Lal i lt i o Brush 3 ces ner gq onvert RME to TME TME Waste ThE Waste Acoustic E j Convert RME Motar 1 Convert EE to AME ala Waste THE Waste Acoustic E Convert EE to RME Waste ThE Wama Acoustic E Motor 3 Convert EE to RME Waste ThE Wasta Acoustic E Power Adapter Battery EE 0 to DC DC import Stored EE wi wi Motor 1 Vike EE Transmit EE Molor 2 Wre Transmit EE Transmit EE Transmit Signal EE Battery remaining time Chaning tme EE Power On Otf Temperature 00000700700000 RD Waste ThE Motor 3 Viro Transmit EE Convert ThE to EE ThE LCD Display 3 PE EE 1 Hd v Battery remaining time Cieening tme EE Tamparature cl
51. American households own a grill or a smoker and it is estimated that they are used on average at least three times a week Design Management from the department of Mechanical Engineering at the University of Texas at Austin asks undergraduate students in their senior year to reverse engineer and redesign a new consumer product that has been recently placed on the market Due to the large demand for barbecue and grilling in Texas one of the most recent inventions has been a grill cleaning robot called Grillbot This product is an automated outdoor grill cleaning device It has more than 20 parts contains electro mechanical elements deals with thermal heat transfer and it has a large user demographic The electro mechanical system as well as the thermal dissipation methods embedded in the Grillbot provides ample opportunities to perform analytical and experimental modeling on the product Additionally because the product was only released in January of 2014 it is only about a 11 year old The immaturity of the product is advantageous to find critical design issues that were overlooked during development The purpose of the Grillbot is to remove the particle buildup from a heated grill without the need for user effort The machine does work by means of three separate electric induction motors that impart torque to shafts with embedded wire bristles The motors rotate based on an algorithm programmed into the controller that random
52. EEE Appendix We Mind Maps Pc ae ADDOIdIX A Eladio Appendix Y Analogies for functional redesign avenue 2 22 Appendix Z Morphological MatriX nes Appendix AA Four bar Mkate inserem ada Appendix AB Fluid Dispenser Location an ORES EAE eee PRCT ACE TIPS paon e a a ETNO Appendix AD CONCEDL V alanis bid Appendix AF Order of Magnitude Calculation sss 20 Appendix AG Specification Sheets ococcccccnnnonccccnnncnnnnnnss Appendix AH Pugh Chalino Appendix AI To Do List and Gantt chart for Phase III Appendix AJ Brush Prototypes ooooccccccccccnnnnnnnnnnnnnnnnnnnos Appendix AK Pictures of Experimental Model Appendix AL Experiment Results Appendix AN Failure Mode Effect Analysis FMEA Appendix AO Updated Bill of Materials Appendix AP Design for Assembly Guidelines Appendix AQ Design for Manufacturing Guidelines Appendix AR Design for Environment DFE Guidelines Appendix AS Final Prototype ooooooncncncccncccnnnnnononnnnnnnnnnss 21 22 PHASE I TASK CLARIFICATION AND REVERSE ENGINEERING Introduction The product offered to redesign and develop is called Grillbot which is an automated outdoor grill cleaning device It has more than 20 parts contains electro mechanical elements deals
53. EOM 10 International Publication Number WO 2013 082046 A2 DO DZ EC EE EG ES FI GB GD GE GH GM GT HU ID IL IN IS JP KE KG KM KN KP KZ LA LC LK LR LS LT LU LY MA MD ME MG MK MN MW MX MY MZ NA NG NI NO NZ OM PA PE PG PH PL PT QA RO RS RU RW SC SD SE SG SK SL SM ST SV SY TH TJ TM TN TR TT TZ UA UG US UZ VC VN ZA ZM ZW Designated States unless orherwise indicated for every kind of regional protection available ARIPO BW GH GM KE LR LS MW MZ NA RW SD SL SZ TZ UG ZM ZW Eurasian AM AZ BY KG KZ RU TJ TM European AL AT BE BG CH CY CZ DF DK EE ES FL FR GB GR HR HU IE IS IT LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR OAPI BF BJ CF CG CI CM GA GN GQ GW ML MR NE SN TD TG 84 Published without international search report and to be republished upon receipt of that report Rule 48 2 g br Organization International Bureau 6 June 2013 06 06 2013 WIPO PCT International Patent Classification Not classitied International Application Number PCT US2012 066678 International Filing Date 27 November 2012 27 11 2012 Filing Language English Publication Language English Priority Data 61 565 268 30 November 2011 30 11 2011 US 13 671 125 7 November 2012 07 11 2012 US Inventor and Applicant WOODS Ethan US US 401 East 81st Str
54. Ga AA ARAYA A gt Actual Functional Diagram 3 i Power Button gt Maria Energy diu eee information EE Electrical Energy ThE Thermal Energy RME Rotational Mechanical Energy TME Translational Mechanical Energy OE Optical Energy AC Altemating Current EE DC Direct Current EE Actual Functional Structure Appendix Q Brush Wheel Thermocouple S oas x 2 x Appendix R Function Component Matrix Components O O gt Sub circuit Brush Motor Shaft Motor wire un O a Cc 9 Ea O gt D co Sub circuit Main circuit wire Transmit RME Transmit EE Transmit Signal Convert EE to RME Convert EE to Acoustic E Convert AC EE to DC EE Convert ThE to EE Import Stored EE Import On Off Signal Import Time Setting Signal Export Torque RME Export on off signal Export Temperature Warning Stabilize Machine Stabilized the Battery Display time remaining to clean Display the battery life Remove food on the grill Detect temperature of inside of Grillbot Regulate Signal x 1 gt II TI Power sutton x eee 1 1 Regulate EE The Thermal Energy EE Electrical Energy RME Rotational Mechanical Energy AC Alternating Current DC Direct Current LCD Liquid Crystal Displays 26 E Functions App
55. Grill Brush seen in Appendix C This industrial strength brush has a 6 x 3 stainless steel bristled cleaning surface and a long angled handle for maximum leverage and reduced work The brush s durable twisted wire surface makes it the most effective grill cleaning brush on the market Its stainless steel frame makes it dishwasher friendly for easy cleaning Perhaps the biggest threat that this brush poses to the Grillbot s success is its ability to clean deeper and between the grill gratings The Rugged Grill Brush offers grill masters everywhere a quicker easier and more efficient way to clean their grill The Grillbot offers the same service making this brush its number one competitor 26 Customer Needs Analysis Mind Map To begin the customer needs analysis we first drew up a basic mind map to understand how the product was being used where it was being used and who it was being used by In addition an activity diagram was formulated that addresses in detail the How of the mind map Based on the demographic and market research we conducted on our product we surmised that it would be consumed as a delight for the purchaser or as a gift People who use this product generally see it as a novelty item This is because the item is not essential for grill cleaning at this point in time Also because of the 130 cost of this item consumers who see the efficiency of a competitor s 10 manual wire scrubbing brush are
56. Interview Summary Sheet Write up House of Quality Specifications Sheet Activity Diagram Visual Diagram Verbal Description Black Box Model Brainstorming Writing Up Hypothesized predicted Functional Model Cross Sectional Sketch 6 3 5 Final Copy of Cross Sectional Sketch Result of Disassembly Disassembly Unscrewing Writing Up Bill of Materials Weighing Components Dimensioning Components Processes and Materials Writing Up Exploded View Taking a Picture of the Exploded View Writing Up Actual Function Structure 83 Constructing Actual Function Structure Function Component Matrix Writing Up Completed Summarization of Reverse Engineering Brainstorming Completed Writing Up Completed Update Specification Sheet and Problem Statement Completed 84 Gantt Chart 5 6 7 8 9 10 11 12 13 14 15 02 02 09 02 16 02 23 02 02 03 09 03 16 03 23 0 30 0 06 04 13 04 20 04 27 04 04 15 15 15 15 15 15 3 15 3 15 5 15 15 15 Week 3 4 15 Status Project Benchmark Phase 1 Start Date Target Date 4 20 15 24 15 0 Product Introduction Background Literature Customer Needs Analysis 02 02 15 09 02 15 100 Customer Interviews House of Quality Specifications Sheet Activity Diagram To do List Gantt Chart Black Box Model Hypothesized Function 2 18 15 2 22 15 100 Model Cross Sectional Sketches Product Disassembly Bill of Materials Exploded Views Actual Function Structure Co
57. Meo of ore gap of bustes 20100531 3 2 7 mm or bristles n ore brush O Total dexww area of Current brah 3 212 22 2 02 174 kdah domna area of New Bash Tata ckanng area of new brush Oss sechona area of kno 5 T area of short extended area Yoss SecHOnal Current brsHe length 4mm Target of roger brisHe Erath J2mm Toga of bng tristes 30 Tagot Of shot bisHes 30 213 319 _ d of ore ap of 2222 4 538 mm Gened owen Tl Ta 1 53843 14 5mm Grass Secharal of shot bastes 30 2 213 111 Simm Cross sechnal area of lang bnstes Jota extended wea 52 435mm Tota cleaning area of new brush 5 111 514 5 6 7 CSIO 295 X 223 02 gt Tre mw brush wll dean an era area of 435mm 175 4 fiom preuas calculation tatal ceanng area of 0 6 0 bush 223 02mm Maximum deanng time of arent molor oues 30mn 18005 2600 Tov et Maximum 09 Ame tren mn Callahan for otahanal Speed 4 Seconds 29 record a reod 4 36 seconds AVERAGE 4 79 Seards ahma i speed _Scycles _ 3 13 des fs 4 305 622 Geles a rotationa Speed 00s 5 Speed 2600s 5 Bagles s 11274 cycles treu rotahanal Area cleoned with motor 5632 x223 02 Area Ceaned with twoet moro 11244 x 223 02 2 twact Cleaning time it wil clam an of
58. One of the patents found that help us to understand the Grillbot more thoroughly is of a battery operated motor in a work apparatus U S Patent No 8 947 024 We know that the Grillbot contains three individual direct current motors that power the rotating brush arms from the description on Amazon com so this patent 15 related because it describes a product embedded in the Grillbot It will help us model the system to address the main complaints of our interview subjects Another patent we found useful for our product is the ceramic coating patent which is used on the wire brushes U S Patent No 7462375 This patent is crucial for our product because if not used the food particles will stick to the wire brushes and prevent motion We could use this patent in the Grillbot on other surfaces other than the wire brushes It could greatly assist in expediting the product cleaning process if we could further reject sediment Another patent related to the Grillbot is from The Sherwin Williams Company U S Patent No 8844087 25 and this patent involves the wire spindles attached to the rotating brushes The patent describes the structural reasons for selecting the number of wires to embed in a bristle Because we have found many complaints already with the work done by these bristles we can use this patent to test different parameters for more effective grime dispersal Lastly we have found a patent for an automatic detergent dispenser U S Patent
59. RAPHY sun RR REFERENCES PP BERGER SOS ee AAPP ill Appendix A To do List and Gantt chart for Phase 1 Appendix B Patent cover PASES A a EARS Appendix GC Rue Sed AA A tat Appendice D ACV DIM ae Appendix E Customer Interview Shet Dossier oa desti Se Appendix E Sussested Price Vs sia dre Appendix G Customer Interview Sheet Dala anne oes weh ate ve Ee axes Appendix H House or Quality HOQ ies Deae eS TURIS Appendix 1 Specheatis sheet seien es Appendix Black BOX Dia si usa HE IR dado Appendix K Brainstorming of Predicted Cross Sectional Sketch esee Appendix E Predictive rossesectional Sketch ann duck esau Appendix M Predicted Functional Structre uneiee a u gas Appendix N Product Disassembly Plan san a eee Appendix O Bikor Materials a a ea Appendix PE xX PlOded VIEW Siueni i o E aries os Lu dc ILU Ce Appendix Q Actual Functional Structure ceccccccccsssssssessssscccecnenennsssssccecccceeeasseesseseceeseaeeeaenees Appendix R Function Component MatriX aeiee eene eene eene a nennen nnn Sas Append x S Nolse absorbine materials seta ee Appendix T Updated Specie atin SNC ae ke Appendix U To do List and Gantt chart for Phase Il sss Appendix VY Picture Sr the Wall ee
60. Sumter Motor shutdown Inefficiencies Physical Daage Cotton conn AT Pis temperature voltage impbalance borken Motor Longevity test 6 4 4 96 A supports and rewind burnout procedures imprecise fonction fulfillment po Come loose Lose contact with ball Housing Motor shutdown Inefficiencies Brush moror shaft Wa LT Fracture Material yield Fatique Abuse misuse overweight sui 11 31 i 15 Different material that is less prone to fracture Brush wheel pf Oxidation inefficiencies Battery Electrical connection failure It wall not charge Battery connection Electrical connection failure It will not charge Redesigned Product Failure Location Component Category Failure Mode Failure Effect It does not create enough friction to clean po Unbalaned Will not clean thoroughly Po Bonding Failure The bristles will fall off brush motor shaft more weight Fracturc Material yield The brush falls off _ 08888 Fineificiencies oe brush falls of Brush wheel difference Inefficient Moor Open Gireuit_ fito operate miss soldering Failure Mode Effect Analysis FMEA Appendix AN 199 OME Original Equipment Manufacturer EE Electrical Energy RME Rotational Mechanical Energy D Diameter Appendix AO Updated Bill of Materials Appendix AP Design for Assembly Guidelines Appendix AQ 1 DFA Guidelines 1 Minimize part count by incorporati
61. a result of changing the control variables we ran some basic back of the envelope Appx AL calculations Because the event of particle removal is so dynamic it was difficult to create a model that could accurately represent the effect of our control variables However since we know that we can predict the static deflection of the brushes based on material and geometric properties we can model the brush bending as a cantilever beam in which the resulting equation 1s 1 2 3El Therefore what resulted were values corresponding to the proportionality of the control variables 6 of the displacement of the end of the beam which we modeled as the depth of penetrating effect and L the length of the bristles Therefore we expect that our long bristle brush will have 2 8 times as penetrating as the original brush We also expect that our added mass will have an additional proportionality of double the depth without the weight attached Altogether we expect the depth to be affected by a factor of 16 59 Of course there are many assumptions made in this model that are not accurate First we assumed that the weight is applied that the end in the horizontal direction which it is not The actual force applied is equivalent to the Psin where is the angular displacement which corresponds to the force and speed applied This model is very nonlinear and would be very difficult to create Additionally we assume the displacement of the bru
62. after the Grillbot s long cleaning process dirt still remained on the edges of the grills because the brushes are not designed to clean them Thoroughly cleaning the grill is important because when food residue is not cleaned well and remains on the grill the food residue will burn when the customers use it again later When food is burnt carcinogenic substances called polycyclic aromatic hydrocarbons PAHs are produced As a result we decided on improve cleaning as our functional redesign avenue Industrial Shift Based on customer interviews customers gave a low rating for quiet noise level and pleasing noise Many customers said the product is too loud to talk comfortably near the grill Therefore we decided the industrial redesign should be noise reduction There are two factors that make noise collision between the device and the wall of grill and the operation of the device s motors Since the noise coming out from collision was louder than from the device itself we mainly focused on reducing noise from collisions 13 For Phase III we determined our parametric interests and experiment responses based on our concept variants and Pugh chart We built prototypes and conducted experiments with the prototypes Then we analyzed data in order to figure out the best prototype Also we worked on a Design Failure Modes and Effects Analysis Design for Assembly Design for Manufacturing and Design for Environment T
63. akes the grill Leaves little residue behind 12 Cleans thoroughly Could easily have handle on top Difficult to take off grill Bristles are hard to clean single button is easy to use I would never buy this it s too easy to clean grill with a simple brush Too expensive and loud Grilling experience level Easy to handle grab Make easier to grab Easy way to clean brushes O2 14 15 16 Intuitive operation Lower price Lower price quieter 18 operation 1 5 c Easy to operate figure out 7 107 2 3 Value Overall rating when cleaning A little hard to get brushes off and back Make easier to disassemble n a 8 10 m 00 Too expensive I wouldn t pay that much Cleaned the grill well I would try and make it a little cheaper and N Make less expensive Effective cleaning Make less expensive while also easier to clean disassemble 13 easier to take brushes off level Easy to operate figure out Overall rating 3 Tasmanian devil in a box 1 7 n a a n 10 Better cleaning maybe longer brushes Cleaned everything but missed the underlying crossbars m Needs to clean better or more with more m N Needs more weight force Cleaning bristles Make easier way to sucks clean brushes Does an effective job Elan thoroughly 14 clean
64. al structure and a predictive cross sectional sketch This is to expand our thoughts and imagination of the product so that it increases the possibilities of redesigning it The teardown step consists of the product disassembly plan the bill of materials and the exploded view In this step we got to see the actual inside of the product and learn how it works Finally the analysis step is composed of the actual function structure and the function component matrix 12 For Phase II we were requested to explore adaptive redesigns of the Grillbot One adaptive redesign should significantly alter the functionality of the product and one adaptive redesign should incorporate a major industrial design change to the product The industrial design change should address an aesthetic ergonomic or style aspect of the product In phase I we formulated five redesign avenues noise reducing material improved brush bristle material increased motor power improved handle and addition of weight House of Quality customer needs analysis and feasibility were considered to finalize redesign avenues for the functional shift and the industrial shift Functional Shift Based on the House of Quality from Phase I effectiveness of cleaning rated high in the relative importance column During the interview one of the customers commented that if the Grillbot were heavier it would clean better This tells us the customer wants the grill to perform cleaner Even
65. alogies Appx Y that gave us ideas to redesign our product The five analogies are car wash toothbrush ultrasonic glasses cleaner dental floss and water jet The first analogy is car wash A car wash is a facility that cleans the exterior of automobiles One of the common cleaning methods is using giant brushes with cleaning fluid dispensers Because our product also uses brushes adding at least one cleaning fluid will make it clean thoroughly like in a car wash Cleaning fluid such as soap is made up of molecules with two very different ends One end of soap molecules is hydrophilic The other end of soap 45 molecules is hydrophobic Hydrophobic ends of soap molecules attach to the oil This will make a drop of oil attached to the grill to be pulled off easily from the surface Soap n d We could design our product to have a soap dispenser We could implement this idea by having a nozzle stick out of the Grillbot having a dispenser at the end of the brush or having a dispenser on the radial part of the brush We gained an idea from toothbrush bristles A toothbrush is a stick with tiny bristles mounted at the tip One uses this to clean one s teeth Some toothbrushes have bristles of various lengths This pattern helps to clean one s teeth more effectively especially given the spaces between teeth The bristles of varying lengths reach the parts of one s mouth where even length bristles cannot reach For example the short b
66. ariant 1 and 5 Concept Variant 2 and 4 Concept Variant 3 Putting them together Write up Pugh Chart Mark the chart Write up Specification sheet and problem statement Spec Sheet for functional redesign avenue Spec Sheet for functional redesign avenue Problem Statement for functional redesign avenue Problem Statement for industrial redesign avenue 130 Write up for Spec Sheet Write up for Spec Sheet roject enchmark hase 1 Product Introduction Background Literature Customer Needs Analysis Customer Interviews House of Quality Specifications Sheet Activity Diagram To do List Gantt Chart Black Box Model 2 18 15 2 22 15 H hesi F i ypothesized Function 2 18 15 2 22 15 Model Cross Sectional Sketches 2 18 15 2 22 15 Product Disassembly 2 25 15 3 1 15 Bill of Materials 2 25 15 3 1 15 Exploded Views 3 2 15 3 6 15 Actual Function Structure 3 2 15 3 6 15 Comparison 3 2 15 3 6 15 Function Structure 3 2 15 3 6 15 Summarize Entire Reverse 3 2 15 3 6 15 Engineering Update Specification h Sheet and problem 3 2 15 3 6 15 100 statement hase 2 To do List Gantt Chart Select Adaptive Avenues Brainstorming Mind Maps 6 3 5 Design Change Concept 3 16 15 3 22 15 100 Generation F ional Re desi unctiona e design 3 23 15 3 28 15 Concept Variants Industrial Design Shift 3 23 15 3 29 15 Concept Variants Pugh Chart Order of Magnitude hase 3
67. ase the operating noise level We then must decide which metric is the most important to alter which is made easy by the Relative Importance column in the customer needs section Overall the House of Quality provides for a simpler visual analysis of how to improve the quality of our product Specification Sheet After completing the House of Quality report we created a specification sheet shown in Appendix I which summarizes the performance and other technical characteristics of the Grillbot We assigned each one of our metrics a physical value such as mass torque or decibel level to establish a baseline target during the redesign processes Additionally a notation of Demand or Wish was assigned to establish each metric s priority if they ever are to come into question We chose the Grillbot for improvement based upon its availability for simple improvements in areas of customer usability and functionality Based on our requirements and the House of Quality our specification sheet also takes into account our concerns about the operation noise levels and effectiveness and time constraints We will use the verification methods mentioned to verify and test our design specifications in order to redesign the Grillbot 32 Using the information from our background research House of Quality and specification sheet we have identified three key problem areas associated with the product The first problem area is th
68. concept is increasing down force To begin analysis of how increasing down force affects the function of our product we extracted two key components that are involved with the removal of matter and associated with down force surface kinetic friction and whiplash force from the bending of the bristle Part 1 Increase kinetic friction forcing The assumptions made for increasing the kinetic friction of the contact between the copper and the grille are e The grill is made of Iron e The relationship F uN is a good approximation of the force of friction because a Contact is always constant between the copper bristles and the iron grille b The friction coefficient 1s constant u 0 5 1 e linearity applies c The surface of the grille is the same everywhere e The mass of the Grillbot is lumped as a 5 kg effective mass The result of calculation using these parameters is that by increasing the downforce with a 5kg mass we can double the force to friction to the surface of the grille from 25N to 50N By increasing the frictional force we are increasing the forcing leverage to removing grime and particulate matter thereby improving the cleaning performance of the grillbot Part 2 Increase whiplash force To calculate the improvement from the resulting whiplash velocity that occurs from the potential energy storage of the brushes we modeled each brush as a cantilevered beam The first step for finding the output velocity 1s to find the stiff
69. corners because this would cause a high stress concentration and significant obstruction of material flow Our bottom shell where the brush wheels are placed under has a sharp corner which could cause a high stress concentration We will apply the guideline when we are manufacturing the redesigned casing by replacing all the sharp corners with fillets that has 67 minimum internal radius of 0 06 inches of the thickness and minimum outer radius of 1 06 inches of the thickness based on the recommendations from the guidelines Telenkom et al 2008 This method will allow the bottom shell to flow consistently without clogging in a sharp corner Design for Environment The design for environment DFE guidelines Appx AS provide ways to reduce the environmental impact of our product We have identified four guidelines that significantly reduce the Grillbot s environmental impact through increasing its sustainability Recycled materials First we will specify recycled materials for the plastic chassis The plastics industry has a very large recycling program Recycled plastic pulls plastic that may have otherwise been thrown away The Grillbot would greatly benefit from sourcing recycled material by reducing its environmental impact while maintaining its function This is according to DFE guideline 2 Using the same materials Along the same lines as the chassis plastic we will specify that the upper and lower chassis parts are made
70. cturing Processes Dimensions E External Parts Depth Width Heizht Diameter Diameter inner 1 Label 1 Display the logo of company 40 4 Ni plated steel Plastic injection molding Stamping the Logo 69 7 12 8 2 Label washer 1 Attaches label to zrillbot 2 6 Zine plated steel Stamped 1 78 18 1 6 51 3 Top shell 1 Enclose components 1642 TC 895 AJB BLACK Plastic injection molding dyed 50 17 5 190 4 Lower shell 1 Enclose components 269 2 TC 895 AB BLACK Dyed Injection molding cut and coated on inside surface 48 5 13 195 3 Pads of lower shell 3 Supports grillbot 3 8 TC 895 AB BLACK Injection molding dyed 43 9 20 4 492 6 Battery Charger 1 Charge the device 1 2 Plastic Steel Cu OEM 76 25 49 30 7 Rubber power button cover 1 Provides soft cushion for button 0 6 Rubber OEM Molded cutting 5 58 14 7 1 Internal Parts LCD display Subcircuit and power buttom 124 1 LCD display 1 Display time remaining to clean battery life Plastic OEM cutting welding and assembled 2 Subcircuit 1 Transmit signal Cu Tin Silicon OEM cutting welding and assembled 50 25 27 12 16 3 Power button 1 Import power on off Plastic OEM cutting welding and assembled 12 Assembly of motors main circuit board power adapter 264 8 1 Motors 3 Convert EE to RME 86 666667 Steel and Cu OEM 58 17 24 8 2 Brush motor shaft 3 Transmit RME to the brush wheels 4 7333333 TC 895 AJB BLACK Injection molding dyed 46 7 13 7 9 1 3 Brush wheel 3 Transmit RME to the gri
71. customers during the interview process marked the noise as a problem In response to these critiques we considered avenues to decrease rattle We are considering attaching noise absorbing materials around the shell of our product In addition to reducing noise adding material to the product will also increase overall mass Since one of our redesign avenues is to create more down force adding noise absorbing material will target multiple customer complaints 42 PHASE Il CONCEPTUAL RE DESIGN In order to maximize organization and efficiency for Phase H we developed an updated Gantt chart and To Do List In the Gantt chart the greatest amount of time was allotted for the brainstorming section of this phase Both of these can be shown in Appendix U Redesign Avenues Considering customer needs analysis Appx G the House of Quality Appx H and feasibility we finalized the redesign avenues for the functional shift and the industrial shift Functional Shift Based on the House of Quality from Phase I effectiveness of cleaning rated high in the relative importance column During the interview one of the customers commented that if the Grillbot was heavier it would clean better This tells us the customer wants the grill to perform cleaner Even after the Grillbot s long cleaning process dirt still remained on the edges of the grills because the brushes are not designed to clean them Thoroughly cleaning the grill is important beca
72. d absorbing shell around the motor because it is cheaper than implementing sensors 56 PHASE III PARAMETRIC RE DESIGN In Phase II we performed conceptual design for our product As a result we developed five concept variants for our functional redesign avenue For Phase III we determined our parametric interests and experiment responses based on our concept variants and Pugh chart We built prototypes and conducted experiments with the prototypes Then we analyzed data in order to figure out the best prototype Also we worked on a Design Failure Modes and Effects Analysis Design for Assembly Design for Manufacturing and Design for Environment We developed a Gantt chart and a to do list Appx Al to organize tasks Parametric Interests In order to create a proper factorial experiment we first needed to identify some factors and responses that best embodied our functional redesign avenue improve cleaning From our previous concept variants we chose varying the length of the bristles as our first parametric interest because it got the highest score on our Pugh chart Appx AH Although increased cleaning time scored second on the Pugh chart it does nothing to really improve cleaning We are interested in better cleaning per unit time so just adding more time is not a real solution Additionally no matter how much time the Grillbot had to clean without changing the weight or bristles it could never reach deep between the grates t
73. did not have a dishwasher The metal bristles gather significant debris and if the consumer were required to clean them by hand it would take more effort than using a standard wire brush Overall we have determined based on 27 the cost of the product the applicability of the product and the requirements of operation that our consumers would need to possess a disposable income to consider this product The activity diagram can be found in Appendix D Customer Interview Planning Process When planning the customer interviews we knew we needed to keep in mind who the ideal customer of our product would be We considered the target demographic as well as how much grilling experience each reviewer had We opted to interview college aged people with varying degrees of grilling experience and desire On each survey we asked them to rate their grilling experience level from 1 to 5 We will use that information when analyzing their responses and weighing customer needs To best record all of the customer responses we decided to give out customer interview sheets that each customer could fill out himself or herself Each person recorded their name grilling experience and opinions on several different criteria We kept each question open ended without steering their opinions one way or the other The interview sheet as found in Appendix E starts with a series of questions that ask the reviewer to rate the Grillbot from 1 to 5 on various aspects
74. dieron una puntuaci n baja a nivel de ruido tranquilo y ruido agradable Muchos clientes dijeron que el producto es demasiado ruidoso como para 17 hablar c modamente cerca de la parrilla Por lo tanto decidimos que el redise o industrial fuera la reducci n de ruido Hay dos factores que causan ruido colisi n entre el dispositivo y la pared de la parrilla y el funcionamiento de los motores del dispositivo Como el ruido debido a la colisi n es m s fuerte que el que produce el propio dispositivo nos hemos centrado principalmente en la reducci n de ruido de las colisiones Para la Fase III determinamos nuestros intereses param tricos y respuestas experimentales bas ndonos en las variantes conceptuales y en la tabla Pugh Construimos prototipos y realizamos experimentos con ellos Luego analizamos los datos con el fin de averiguar el mejor prototipo Adem s tambi n trabajamos en un An lisis de los modos y efectos del fallo de Dise o Dise o de la Asamblea Dise o para la Fabricaci n y Dise o para el Medio Ambiente A trav s de toda la experimentaci n an lisis dise o y creaci n de prototipos hemos hecho un Grillbot que limpia mejor que antes Durante la experimentaci n y el an lisis param trico posterior hemos demostrado que las cerdas m s largas y un mayor peso mejoraron la funci n de limpieza Se utiliz el an lisis estad stico para representar gr ficamente la correlaci n entre aumento de rendimiento
75. dimensions of the brushes We want to increase the length of half of the bristles from 9 mm to 12 mm which will increase the cleaning area of the brushes and therefore the total area of the grill being cleaned Pugh Chart We used the Pugh chart Appx AH to methodically compare the concept variants We considered increasing the weight modifying the brushes adding a water dispenser increasing the cleaning time and adding a water jet We evaluated each of these variants based on the following criteria purchasing cost cleaning time development risk durability maintenance ease of use battery life and most importantly cleaning ability In deciding on those criteria we consulted the House of Quality and customer needs interviews we performed in Phase 1 as well as our own engineering judgment In rating the concept variants on each of those criteria we used the scale of worse than same as 0 or better than Each concept variant acts as the datum in one of the five Pugh charts in order for each variant to be relatively compared to the others With increased weight as the datum most other options will cost more because of their relative complexity with the exception of adding run time Because adding weight increases the cleaning force it cleans about as quickly as modifying the brush quicker than the water dispenser and the adding of run time The use of the water jet 1s the only option that cleans more quickly than increasing
76. ds to grill Soundproof cover perimeter Change material N Soft Increase bumpers sturdiness Play Dough Foam Cork Soundproof blanket Soft Plastic Secure lid better Rubber Spri Rubber DUE 134 Appendix X 6 3 5 Industrial Redesign Avenue Hayden ORANGE Mark RED Maria LIGHT GREEN Mark BLUE Sean PURPLE Non J students 135 136 lenge Te gt EN E 3 7 priu A e i E 6 SPRING 0 DE Ses CONCRETE ir Force PUR oe EN CLOSJ ALUM teg i P 5 Pike To edciene e ill y Ue CS Vie Poet ayes pii SAC DAMPER 1 2 60 PEA 1 COLLIS jay ee NiSCoUS 7 et up s Ms Noise REDAKTION 137 LouLD BE STICIC Eie Y LC e per by body equi nes mort 4 tema ik clang steel OR ge Compos TE Li Oiio 138 7 A w A Lo Fhe Bi WV Ag Posible Y D J 139 o install 140 Noise 06 d Mul Li e S length pals dd dE e sey sts hee ceda deep hai ollo Starts to Ate Y wails lt 0 5 ee b orl e gut abst blanket might get dirk 141 ape ro C C bum yn A Wee Ba RESISTIVE Functional Redesign Avenue J
77. duct as well as decrease the manufacturing cost Design for Manufacturing We applied design for manufacturing DFM principles to optimize cost reduction efficiency and ease of manufacturing Additionally we can improve quality control procedures We can achieve these goals by using standard dimensional variable capabilities when determining the tolerance for our components Telenkom et al 2008 Provide a draft angle For the casing of our product injection molding was used to manufacture them The casings are the handle the upper shell and the bottom shell The design guideline in Appendix AR for injection molded parts suggested us to provide a draft angle for easier mold removal If there is no thickness for draft it might be hard to get the parts from the mold and parts will end up torn There is some complicated shape on the back of the handle Those shapes are also small and complicated therefore they might cause fracture when the manufacturer is removing the handle from the mold Also on the bottom shell where we put in the bottom pads on the angle is 90 degrees which could cause fracture during removal from the mold We will allow a minimum draft angle of two degrees to these features The small draft angle of the handle will help facilitate its manufacturing while keeping its shape and the ability of the product Telenkom et al 2008 Avoid sharp corners In Appendix AT the guideline recommends us to avoid having sharp
78. dup soft food overweight overuse visual 11 312 D Different material that is less prone to wear 2c 15 48 umm 10 Fatique Abuse visual 1 1 712 Different material that is less prone to wear Corrosion visual 6 4 6 144 Different material that is less prone to oxidized misuse faulty electrical connection voltage test 3 7 3 63 Store under proper position misuse faulty electrical connection oltage test 11 7 31 21 Have stronger port t P alejes Jeje ej ajej Jats gt h un Current Situation Current Detection Failure Cause Suggested Remedial Measures Steps hardware failure 36 Develop a different pattern human error ve 2 6 AR Proper measurement prior o manufactur misuc abuse visual 5 7 6j 210 Usc a stronger glue material Improper material choice visual a 5 6 120 Different material that is less prone to fracture Improper installation 4 s e 0 Proper measurement prior to manufactur Improper installation visual 4 5 6 120 Proper measurement prior to manufactur voltage test a 8 8 256 Solder neatly Sa Failure Location Component Main Circuit Owverheat inefficiencies fail to operate Po Soldering failure inefficiencies fail to operate Power button Wer cannot start the machine oo fer cannot start the machine Category Failure Mode Failure Effect Mom
79. e an average characteristic grate size Based on those results we turned down a steel rod to a diameter of 0 25 inches to act as the grill grate 58 We made several parts out of aluminum in the machine shop including the sliding plate which the motor and brushes mounted on and the brush adapter which uses a setscrew to connect the test brush to the motor shaft The sliding plate rested in a channel in the brush mount restricting the direction of the brush in only the z direction We made the aluminum adapter for the brushes 1 03 inches in diameter It was slightly larger than the interior diameter of the PVC to be able to force this inside of the brush body Nevertheless after forcing in one of the brushes we realized that it was an extremely tight fit and in order to switch the brushes we would have to saw the PVC to increase the allowance of the diameter Therefore we tested the first brush that has even length and sawed the second brush which has various length of the bristles to put it in When we did the tests with the weight we simply hung a 6 50z mass on the plate To run the motor we connected it to the DC power supply and fixed the voltage to around 12V We measured the voltage provided by the Grillbot itself and 1t was approximately 7 62V but we decided to increase this to 12V to make the motor go faster and increase the cleaning effectiveness Calculation In order to predict what the results of our experiment would be as
80. e ceder estos derechos en la forma prevista en la presente cesi n y as lo acredita 2 Objeto y fines de la cesi n Con el fin de dar la m xima difusi n a la obra citada a trav s del Repositorio institucional de la Universidad y hacer posible su utilizaci n de forma libre y gratuita con las limitaciones que m s adelante se detallan por todos los usuarios del repositorio y del portal e ciencia el autor CEDE a la Universidad Pontificia Comillas de forma gratuita y no exclusiva por el m ximo plazo legal y con mbito universal los derechos de digitalizaci n de archivo de reproducci n de distribuci n de comunicaci n p blica incluido el derecho de puesta a disposici n electr nica tal y como se describen en la Ley de Propiedad Intelectual El derecho de transformaci n se cede a los nicos efectos de lo dispuesto en la letra a del apartado siguiente 32 Condiciones de la cesi n Sin perjuicio de la titularidad de la obra que sigue correspondiendo a su autor la cesi n de derechos contemplada en esta licencia el repositorio institucional podr a Transformarla para adaptarla a cualquier tecnolog a susceptible de incorporarla a internet realizar adaptaciones para hacer posible la utilizaci n de la obra en formatos electr nicos as como incorporar metadatos para realizar el registro de la obra e incorporar marcas de agua o cualquier otro sistema de seguridad o de protecci n b Reproducirla en un s
81. e easily We considered using water or cleaning fluid The team decided that cleaning fluid 15 more beneficial because the dirt attached to the grill is mostly oily residue The cleaning fluid can reduce the surface tension between the grill and the dirt making it easier to remove Having fluid dispensers is a feasible idea we could have the fluid dispenser on a radial or axial position Appx AB Adding a water jet is another good idea Shooting water at a high pressure will easily remove dirt on the grill but the cost to implement this method would be expensive To convert EE to ThE we imagined using induction heating resistance heating laser steams or radio waves Induction heating and resistance heating could be used to soften food particles Another idea is that we could shoot lasers and burn down the dirt on the grill instead of using brushes Using steam is similar to using dispensing fluid It will soften dirt and it will come off easily Steam is the most feasible idea because implementing laser equipment would cost too much and using a heating element might cause the device to melt or even burn the grill To convert EE to vibrational energy we considered having an ultrasonic bath on our device It will use sound waves of frequencies 20 80 kHz Ultrasonic n d However the bath should be big enough for the grill to be immersed in which 18 impossible That would change the Grillbot into a completely different device Additionall
82. e loud sound produced in the grill during a Grillbot cycle We intend to address this problem through design inclusion in the area of vibration dampening Another main problem area we found was the effectiveness in food particle removal We intend to address this problem by redesign in the area of torque applied as well as design implementation of some additional fluid cleaning aid Finally we identified customer dissatisfaction with the general accessibility of the product Because some grills have low clearance sections and small surface areas we are interested in redesigning the critical geometries of the outer shell Also a problem associated with accessibility was directed towards the main carrying handle which can be resolved with a more ergonomic design We then started conducting reverse engineering of the Grillbot Reverse engineering helps you learn about a product and it follows three basic steps prediction teardown and analysis In the prediction step we created a black box model a hypothesized functional structure and a predictive cross sectional sketch This 1s to expand our thoughts and imagination of our product so that it increases the possibilities of redesigning it The teardown step consists of the product disassembly plan the bill of materials and the exploded view In this step we got to see the actual inside of the product and learn how it works Finally the analysis step is composed of the actual function structure and
83. e radiant heat Because radiation and conduction are the key elements of heat transfer to the Grillbot we need methods to analyze the temperature gradients associated with the machine components This textbook is by Incropera Bergman and Lavine The main author Incropera is currently the Clifford and Evelyn Brosey Professor of Mechanical Engineering at Notre Dame The two other authors Bergman and Lavine also have degrees in engineering This book 1s commonly used in academic institutions for classes such as Heat Transfer and Thermal Fluids Systems This book did not target any particular private companies or institutions but to share information with colleagues in heat transfer community This source is relevant because we are dealing with Grillbot which cleans a hot grill Our team is interested in increasing the thermal capacity of the Grillbot In order to do that we need to know the temperature distribution through different media based on heat flux to prevent melting or destroying the product due to radiation In addition the polymer wheels are in direct contact with the heating element which is influenced by direct conduction Finally the internal electrical components are also of particular concern due to their vulnerability to excessive heating 2 Karnopp D amp Margolis D 2012 System dynamics modeling simulation and control of mechatronic systems Sth ed Hoboken Wiley Because many of the embedded systems i
84. eased weight improved the cleaning function We used statistical analysis to plot the correlations between performance increase and concept variance change With this data we can conclusively recommend the implementation of bristle lengthening and down force increase for a simple inexpensive and efficacious redesign After performing FMEA we found the various modes of failure and ways to lessen the chances of them happening By considering DFM DFA and DFE we identified other ways to improve the Grillbot such as better manufacturing assembly and use Finally based on our experimental results we built a final prototype This functional Alpha prototype represents the semester long body of work we put towards the Grillbot Finally this class has been valuable to my future career in so many ways First I have learned the tools necessary to approach a design problem By thoroughly understanding the customer needs and strategically selecting redesign avenues I now have procedural direction when faced with a design challenge By discovering the features of the Grillbot that the customers were dissatisfied with I gained a methodology for clearly defining the problem without biasing the main goal with practical feasibility consideration I also learned how important it is to fully understand a product through benchmarking and dissection Understanding how the product works as well as how its competitor s product works is crucial to the preliminary stage
85. een the two structures was the inclusion of a sub circuit that controls the power button and the LCD This secondary circuit board is located underneath the LCD and the power button This circuit board produces the information on the LCD Function component matrix The function component matrix Appx R shows the components of the product and their corresponding functions A cross x marks components with that function The matrix shows for example how the battery cushion pads stabilize the battery by helping the battery to stay in place and protecting it At the same time the bottom pads stabilize the product supporting it when the brush wheels are not in place They help the Grillbot to stand still and they make it sturdier The Grillbot should not get too hot so the thermocouple detects the temperature of the inside of the Grillbot The main function of the motor wires is to transmit electrical energy from the main circuit to the motors We used the function component matrix to build our actual functional Structure Summarization of Reverse Engineering We use reverse engineering to know a product inside and out Knowing a product on this level reveals flaws or weak points in its structure leading one to determine and act on opportunities for redesign This project is no different We performed thorough reverse engineering on our product ultimately to determine potential avenues for redesign The first part of the reverse engin
86. eering procedure was the prediction step which consists of deduction and inference to hypothesize the product design We performed this analysis through predictive modeling which includes the black box model Appx J the predictive cross sectional sketch Appx L and the hypothesized functional structure Appx M 39 The next part of the reverse engineering is the teardown which involves taking apart the product to determine its internal structure and how it actually functions While performing the teardown we recorded the steps of disassembly and named each of our parts based on their function Appx N Once disassembled we took pictures of all of the parts for the exploded view We created a bill of materials table Appx O to list the characteristics of each part After teardown we constructed the actual functional structure and our team compared it to the hypothesized functional structure The purpose of this analysis is to support the next stage of the reverse engineering process and eventually the conceptual design phase of this project Throughout the prediction and teardown steps we were consciously looking for potential avenues for redesign We used customer needs analysis to narrow our scope to specific redesign avenues For example most of the customers listed noise level of the product as an issue for the product In response we discussed noise reduction as one of our redesign avenues We concluded that the sound is not a
87. eet PHA New York New York 10028 US Agent PRINCE Kevin 2580 Anthem Village Dr Henderson Nevada 80952 US Designated States unless otherwise indicated for every kind of national protection available AE AG AL AM AO AT AU AZ BA BB BG BH BN BR BW BY BZ CA CH CL CN CO CR CU CZ DE DK DM 43 International Publication Date 51 21 22 25 26 30 72 71 74 81 54 Title SURFACE CLEANING DEVICE FIG 1 57 Abstract A device for cleaning a surlace such as a barbeque grill has a substantially hollow enclosure that has at least a lower side an upper side and a peripheral edge and contains a plurality of motors that each has a rotational shaft selectively fixable with a rotatable brush At least a portion of bristles of each brush projects below a plane of the lower side of the enclosure The enclosure 7 gt E E LU 7 2 a 8 e gt Fa b 3 e 5 E 3 E 2 Tr 3 e 8 5 3 e gt 2 S v e 2 A 3 e a 2 gt tuation of an electrical switch connected thereto The circuit is adapted to run each motor in a first direction and then an opposing direction such that if the device becomes stuck at an obstruction it will eventually turns around due to the alternating directions of the motors 90 013 082046 A2 2 3
88. ements 7 16 24 28 31 33 55 Ensuring that destructive disassembly techniques u Ra 4 31 32 56 Ensuring reusable parts can be cleaned easily and without damage 4 57 Ensuring that incompatible materials are easily separated 6 8 31 32 58 Making component interfaces simple and reversibly separable 6 8 25 31 33 59 r IE ES E 16 25 28 60 Implementing reusable swappable platforms modules and components 4 6 8 29 32 61 Condensing into a minimal number of parts 5 9 30 32 62 Specifying compatible adhesives labels surface coatings pigments etc which do not interfere with cleaning 5 8 16 25 28 31 33 63 Employing one disassembly direction without reorientation 7 16 25 31 64 Specifying all joints so that they are separable by hand or only a few simple tools 7 16 25 31 32 65 Marumuzing the number and length of operations for detachment 16 31 66 A AA pen ern 5 8 9 16 25 28 30 31 33 67 Using a shallow ar open structure for easy access to subassemblies 7 203 Appendix AS Final Prototype 204
89. emoved the handle from the top shell and detached the LCD and the power button We pulled out the power cord from the main circuit and unscrewed it from the top shell It was easy to take out the battery and the battery cushion pads from the device We unscrewed the shafts from the lower shell in order to separate the motors After we removed the motors we unscrewed the bottom pads from the lower shell and the label from the handle We used our hands and screwdrivers to detach the thermocouple from the lower shell which was mounted with epoxy Bill of Materials The purpose of the bill of materials Appx O 1s to analyze the internal components of the product It is a complete catalog of each individual part of the product It provides a wide range of 36 information for each part including its function dimensions material manufacturing process mass and quantity Understanding each part helps us gain a thorough understanding of the product as a whole It also provides for organization and consistency in our analysis of the Grillbot throughout the reverse engineering process In order to determine names of each part we considered their location and function in the Grillbot For example the pieces that connect the brush wheels to the motor were named brush motor shaft We used an electronic scale to measure the mass We briefly described the function of each part The battery function for example was described as Import stored EE
90. endix 5 Noise absorbing materials Extreme Vibration Attenuation EVA pad 7 105E 03 Sound Dampening Pad 2 165E 02 RB Rubber 1 083E 04 AcoustiCORK RR300 8 476E 06 5mm Pre Cut Rubber 1 559E 05 127 Appendix T Updated Specification Sheet Demand mm em Geometry Verify with dimensions given by the 15 02 15 Volume 241 164 Inches 3 l Engineering sketch Kinematics 07 03 15 D Rotation Rate of Wheels rpm Al Verify with output torque of motor Force 0 o Mass en EN 7 Measure Weight with a digital weight scale Material 15 02 15 D Strength of Wire Brushes gt 600 Mpa All Test through Tensile Strength Test Assembly 07 03 15 W Number of Parts lt 25 A Count number of parts used Operation Measure noise with phone Application Noise level of beeping Measure noise with phone Application lt 40 after shut down All dB Cost 07 03 15 07 03 15 15 02 15 Expected Cost of Product All From customer interviews Schedule 15 02 15 Average time to wash sio nutes All Measure time required to clean brushes the brushes with stop watch 3 times Time of Beeping after 15 02 1 lt 5 S d All og os BENE C lt s seconds al Measure time with stop watch Time to ch th 15 02 15 dd 4 Hours All battery From the instruction user manual Signal Actual time it takes t ti ired to cl the grill 15 02 15 ctual time i al esto _ EEE easure ime required to clean the gri clean the grill with s
91. ent DC Direct Current IX Matr 1Ca Morpholog Appendix Z Appendix AA Four bar linkage Chebyshev linkage Left and Hoekens linkage Right 157 L1 Appendix AB Fluid Dispenser Location a Fluid dispenser on a radial position of brush b Fluid dispenser on a axial position of brush 158 Appendix AC TIPS Feature to improve 3 Length of moving object Undesired results conflict 9 Speed Principles 13 Other way around 10 4 Asymmetry 24 8 Counter weight 32 159 Appendix AD Concept Variants Functional Concept Variants AN gt a Se masse HI ody 00 Change Material A Grillloo 1 has o bigger 4n oss EQ longer oristies Stronger ty pes of materials X 3 FLUID NOTELE gt CLEANING FLUID CoNTAIN Ge 160 INCRE ASE RUN TIME WATERIET Ly a Pa s A 1 A LAAAMA Uu nite Ammon A TEMP DER THERMAL ENERG From 10T GRILL PRESSURE E a PON CoN TK N ER 161 Industrial Concept Variants 2 Bumper So Materias L Cork etlo sure Brush wheel Encl osu Brush wheels lt a DAMPER PNEUMATIC ALUMINUM SPRING SOFT MATERIA SHAFT LENGTH I EXTENDED Sponge SSS WEE ATTACH Sor MATERIA O ENDS oF BRUSHES CORK IR PRox m SENSOE 70 ACE DECREASE MASS 8 860 5 WaTERIAL From wails
92. erial to the empty space inside or add magnets to the bottom surface which would pull the Grillbot to the steel grill 50 The second concept variant is modifying the bristles By lengthening the bristles we would increase the probability of removing lodged matter from between the bars as well as increasing the surface area of affectation for the top planar surface This design would be easy to implement with manufacturing because there are no extra parts to source The third concept is using cleaning fluid Because the grill becomes oily after grilling we think using cleaning fluid would get rid of oily dirt easier The dispenser could be gravity fed using the fluid pressure to push the fluid out similar to a generic squirt bottle The next concept variant is increasing cleaning time Increasing the running time of the Grillbot allows more passes over the surface As the number of passes increases the probability of having an untouched area decreases We can find motors that allow the device to run longer The last concept variant is using a water jet If high pressurized water were shot towards the grill the force of water jet would act on the food particle which would create a shear force This would strip off the food residue Also it can reach the spaces between the bars In order to adopt it to our device we need a portable air compressor that could pressurize a container of water so that the output of the nozzle would be suf
93. ermine Parametric Interest Write up To Do List Phase 3 To Do List Gantt Chart Parametric Interest Develop Experimental Model Design experimental setup Fabricate experimental setup Design factorial experiments Back of the envelope predictive calculations Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Write up for experiment Conduct experiments Analyze experiment results Compare results to prediction Write up Table for original product Table for redesign product Write up Make Slides Intro Customer Interview Redesign Avenue Low resolution prototype Result Record Video Put them together Scan pictures Write up Experimentation FMEA Presentation Design for Assembly Design for Manufacturing 188 Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Scan pictures Write up Revise BoM Write up Model prototype on Solid Works Buy material 3D print prototype Design for Environment Preliminary Drawings Revision of BoM Extra Credit Provide recommendations for future redesign work 189 Week 3 4 5 6 7 8 9 10 11 12 13 14 15 16 02 02 09 02 16 02 23 02 02 03 09 03 16 03 23 0 30 0 06 04 13 04 20 04 27 04 15 15 15 15 15 15 15 3 15 3 15 5 15 15 15 AE Status 96 roject enchmark hase
94. ers want it to be heavier so that it can clean more effectively Likewise our team wants the strength of the wire brushes to increase so it can get rid of the heavier grime left on the grill grating We would also like to increase the rotational velocity of the brushes the faster the rotation the more strokes made by the brush On the customers interviews they complained about the Grillbot s price so 31 we Set the target value of cost to 60 which is a half of its current price For operating noise level and beeping after shut down we searched the desirable noise level for operating noise of computer We think this noise level is comparable to the noise level we wish to achieve for the Grillbot We did not find a large amount of complaints on the color and volume of the Grillbot so we decided the target values can remain the same as the current values In the final section we demonstrated how the alteration of one metric might affect the value of another metric In order to determine this we used the same method we used for the interrelationships section For positive relationships we used check marks and for negative relationships we used X marks Once again the boldness of the marks indicates how strong the relationships are As previously mentioned this section of the HOQ helps us to see how one metric affects another For example we want to increase the rotational rate of the wheels but this would incre
95. es much more maintenance Simply increasing time is inexpensive and easy but does not solve some of the biggest requirements It does not clean better or faster than any of the other variants while using more battery life As a result we found a few solutions that rise above the others Adding all of the new totals together gives the rankings from best to worst variant modifying the brush 17 points increasing cleaning time 11 points increasing weight 4 points adding a water dispenser 11 points and adding a water jet 12 points Though some of the variants scored very poorly combining multiple concepts into one can round out the negatives and provide very good cleaning power Problem Statement Functional Shift Based on our House of Quality we will improve cleaning of the Grillbot The five concepts are increasing weight modifying the brush using a water dispenser increasing cleaning time and adding a water jet Based on our order of magnitude and Pugh chart we decided modifying the brush is the best idea to improve cleaning Industrial Shift 55 Based on customer needs analysis we will work on noise reduction Five concepts we have came up for this are adding soft bumpers modifying the brush adding sensor decreasing the mass adding sound absorbing shell around the motor Decreasing the mass is conflicting with improve cleaning therefore we want to avoid it Finally we want to try adding soft bumpers and soun
96. est source of energy 5 7 25 31 14 Including labels and instructions for safe handling of toxic materials 7 9 29 33 15 ARRE ri Te 16 29 30 for e 24 Principle C Ensure minimal use of resources in production and transportation phases by 24 32 17 Replacing the functions and appeals of packaging through the product s design 7 25 18 fy porn 25 rarest rt r gia 16 24 25 28 30 32 materials and 6 8 16 25 beit 22 ional surface treatment or inks 5 7 25 rn ren AGG 7 16 25 Minimizing the number of components 7 16 25 31 Specifying materials with low intensity production and agriculture 8 25 Specifying clean high efficiency production processes 5 8 16 25 30 Employing as few manufacturing steps as possible 30 Principle D Ensure efficiency of resources during use by 5 9 21 27 Implementing reusable supplies or ensuring the maximum usefulness of consumables 5 7 10 16 25 28 Implementing fail safes against heat and material loss 7 10 25 29 31 29 Minimizing the volume area and weight of parts and materials to which energy is transferred 7 10 25 31 30 Specifying best in class energy efficient components 7 8 10 25 29 31 31 Implementing default power down for items that are not in use 5 7 25 31 32 Ensuring rapid warm up and power down 10 33 Maximizing system eff
97. etachable from the body and attaches the scraper to the body for use We could use their idea that detaching brush and putting the scraper on it so the Grillbot scrapes off foods crumbles that are stick on to the grill pan 5 Matz W W 1998 U S Patent No 5839454 Washington DC U S Patent and Trademark 79 Office The US patent issued to Matz is an automatic detergent dispenser for residential dishwashers allowing transferring detergent from a container or an integrated storage receptacle to the dishwasher The innovative part of this invention is that the user can adjust the amount of detergent to be dispensed This patent includes pictures of how the container is attached to dishwasher and the connection of cords between containers to the dishwasher This invention contains an electric pump which operates on a timer used in conjunction with an existing dishwasher wherein the pump transfers liquid detergent from a container through the side wall of a dishwasher The dispenser also contains a sensor which determines whether the liquid level within the container has fallen to a point that requires replenishment and alerts the user to this condition by use of a light and of an alarm mechanism A grill is where food is roasted on Hygiene is important because there could be bacteria that survive at high temperatures and oil that sticks to the grill pan can be hazardous to humans It would be great if the Grillbot could inject soap w
98. ficient for removing organic matter Concept Variant for Industrial Redesign Though the motors do produce noise most of the noise comes from the collision of the Grillbot against the sides of the grill To address the collision noise our first concept variant is a spring with shock absorbing material on the outer surface The premise of this design is to simulate a mass spring damper system which is commonly used for signal and vibration attenuation The spring will store most of the energy of the impact and the damper cushion material will absorb some of the energy and soften the impulse We will implement this idea by bending a thin aluminum sheet with a carpet material attachment on the surface damper and attaching it to two soft springs that are connected to the edge of the shell We will add three of these systems at 120 degrees radial separation to ensure all sides are protected from impact We could lengthen the shafts that connect the brushes to the motors to prevent the device body from colliding with the grill lid Also we could add a soft material or bristle over the end of the brush to reduce the collision sound This concept is rather simple because we only need to extend the length of the shafts or add materials over the end of brushes 51 The next concept is decreasing the thickness of the device body Decreasing the thickness of the device of the body would decrease the mass which would decrease the impacting noise The
99. fourth concept is using sensors so we completely avoid collision One of the most inexpensive yet effective forms of sensor detection is an infrared sensor which has emitting and receiving transmitters If we applied three of these sensors which would have a 120 degree field of view and in a 120 degree radial orientation we could have the motors change direction before impact thereby eliminating sound generation altogether The last concept is adding sound absorbing materials around the motor to reduce the noise coming out of the motor This would be inexpensive and in coupling with one of the variants above could reduce the majority of operation noise Low Resolution Prototype There were many ideas of changing the shape of the bristles As it has a crucial role in cleaning because it directly cleans the grill we decided to make low resolution prototypes on the brush The construction process can be found in Appendix AE Prototype 1 has even length bristles aligned in a straight line Prototype 2 has uneven lengths aligned in a straight line as well Both prototypes will be able to clean the edges of the grill We designed uneven bristle lengths because when the motor is running fast the even length brushes might not clean the edges of the grill After we finished building them we showed our prototypes to potential customers and received feedbacks Three of them liked prototype 2 because they think the longer bristles can clean the edges
100. ght of adding pads around the inside perimeter For the body of the Grillbot we considered changing its material or adding a soft bumper to reduce the collision noise We could also change the original motor and decrease its speed or we could simply add sound absorbing material around the motor The brushes could be modified in two ways by adding bristles over the ends of the brush or making the brushes longer so that it reduces the sound of the collision Since most of the noise is produced due to collisions we could install radars IR sensors and probes to avoid them Functional Redesign Avenue Similarly the functional shift mind map branched out from Improve Cleaning The concepts that branched out from the center of the map were increasing friction cleaning dispenser changing brushes increasing cleaning duration and adding mini robot and ultrasonic cleaning Cleaning has to do with friction If there is more friction the device can remove the dirt attached to the grill more effectively If our device had a cleaning fluid dispenser fluid could soften the grime by decreasing surface tension and wetting the dirt which helps to clean it better Naturally we would use a cleaning fluid dispenser however the fluid would decrease the friction between grill and the device Therefore we need to experiment the effectiveness of both ideas We could also redesign the brushes to have different materials different patterns geometry
101. gnal to its motors In addition we assumed there are three independent motors that rotate each brush wheel Shafts that translate rotational mechanical energy connect the motors to the brush wheels The controller also sends a signal to the Liquid Crystal Display LCD and the speaker When the LCD gets a signal 1t would light up and give users information such as the remaining battery life and cycle time The speaker would also do that same action It would make 34 acoustic sound that gives us information The controller also includes the thermocouple which detects the temperature of the inside of our device The predictive cross sectional sketch expands our thoughts and imagination of the inside of our device and visualizes the enclosure It helps us in redesign because our prediction could contain a better or cheaper processing idea Hypothesized Functional Structure The functional diagram is an expansion of the black box diagram and is based on our predictive cross sectional sketch It takes the same kinds of energy material and information inputs and outputs and separates them into the individual parts and processes of the product The functional diagram allows us to see the inside of the product and recognize energy flows and information transfer It also shows each point of energy conversion These points are important in recognizing where potential energy losses from friction and noise can occur The hypothesized functional structure
102. gt Me Na 7 0 5 100 SON coefhaent of friction ASSUMV 9 we dable the mass we dable the ner Aich feSgonse 9 ACEEASING FRICTION INCREASES THe ZUBBING FCE OF THE BRAISTIES PARTICLES RAT HAVE STICKING foeces MELEN EENOnNG MORE Massume bishes act as m deal entlever beam in bering f 0 Ut ee er OTe relakonship f this static relahonsmp is f KX gt Tre force V lS myoma de He amount of down force kKecause as yu mame tHe bod the deflection a the bristles also increases 1 d brush Ginder 171 The eey stored tre pistes s te aram OF 0 released fv m ck spring the AE TERT The eey um be coveted Eneic energy assuming all of erway 5 released oe te force Is remwed c Zlr u 0 gt EX Xs We wl be moreasma tre stored erevay by 6 0 the beams nihal displacement Ymoe Therefore we will also be increasing Vmax So lets S or ENERGY Wi AND WIO FOCE PPRUICO No farce aped f kX Athhonal foce applied f kX x gt Xo E 2 2 z r zm Vo Xo EA gt Yo 2mv Ut E y MALSE IMPALTED 0 p my 000 MASS hd4 gt A Assumag di Constant mer Y F dt unen moe ac added we wll rye PACES With add horal down face Pero Vabes Aer canduchng a defiechon ESE of 4 grup of bistes we found tHese w
103. h 2 15 15 NS Time of Beeping after shut down EN Measure time with stop watch 2 15 15 LE Time to charge the battery lt 1 hour nuc stop 115 Appendix J Black Box Diagram ThE Acoustic E RME Vibration E Waste ThE Optical E Hand Clean Grille E rll Food Particles Power on off Battery Life Time remaining to clean Pe gt KEY gt Energy input output Material input output Information gt E Energyinput output EE Electrical Energy ThE Thermal Energy RME Rotational Mechanical Energy 116 EE ThE Hand Dirty Grille Set Time Power on off Temperature of Grill Appendix K Brainstorming of Predicted Cross Sectional Sketch 117 Appendix L Predictive Cross Sectional Sketch Motor 1 Power on off Button Time Setting Button Brush motor Shaft 1 LCD display uz Displays the bttery fife and Motor Wire 1 time remaining to clean gt B me Controller oF 8 J Brush Wheel 2 I pe ity uM Gy 3 7 _ a ne 5 E Lo QUT Thermocouple c i 9 en Motor 3 18 i eee t Brush motor Shaft3 j Brush motor Shaft2 Motor Wire 2 N Battery for GrillBot Ca rechargeable Brush Wheel3 A un i bos AC to DC converter Cord Power Plug Thermocouple detects temperature inside of
104. hen the weight and length of the bristles were increased was greater than all of the other trials for both data values This trend correlates to our hypothesis that increasing both of the variables will symbiotically improve performance On the other hand the length data does not support the cubic proportion we had assumed in our back of the envelope calculations 61 There are many reasons that our experimental results were not what we expected from the back of the envelope results First the back of the envelope calculations assumed that the depth would be solely a function of the displacement in the x direction of the modeled rod That assumption is entirely incorrect There are many interacting phenomena as suggested earlier that demonstrate a much more weighted affect That being said these variables outside of our model are still functions of our control variables just not in the proportions we assumed In addition to the unaccounted factors the number of data points we have are insufficient to draw any strong conclusive argument We can analyze the data and point out the trends but we cannot say with a degree of certainty that these trends will continue Furthermore if we were to collect more data we believe that both response variables will align with our fundamental hypothesis that increasing the control variables will improve depth and surface area contact Statistical Analysis In order to better interpret the acquired data we
105. hile it is cleaning so that it could get rid of all the dirt and oil Also Grillbot could be used in a variety of ways therefore if 1t has this function customers would be more satisfied to clean other surfaces 80 REFERENCES Plastics Processes 2015 Retrieved March 6 2015 from http www bpf co uk plastipedia processes Default aspx Woods Ethan 2012 U S Patent No WO2013082046 A2 Washington DC U S Patent and rademark Office https www google com patents WO2013082046A2 dq ininventor 22Ethan WOODS 22 amp ei AeXQVMW_DcKfgwS4ro04DQ amp cl en Cancer and Food 2014 March Australia Common Laboratory Flammable and Combustible Chemicals 1991 Retrieved from SAN DIEGO STATE UNIVERSITY http bfa sdsu edu ehs pdt CommLabFlammable pdf Electric Motors Pump Motors 2015 Retrieved from WEG easy http www weg net us Products Services Electric Motors Pump Motors Factors to consider when choosing the best toothbrush n d Retrieved April 5 2015 from http learn medical com factors to consider when choosing the best toothbrush Helmenstine A 2014 December 4 How Detergents Work Retrieved April 4 2015 from http chemistry about com od howthingswork f detergentfaq htm Linear Guideways 2013 Retrieved from HIWIN http hiwin com html linear o20guideways Manual toothbrush n d Retrieved April 5 2015 from http www toothclub gov hk en en_adu_01_03_01_02 html Panagakos F S amp Migliorati C
106. hrough all of the experimentation analysis design and prototyping we have made a Grillbot that cleans better than before During experimentation and the subsequent parametric analysis we proved that both longer bristles and increased weight improved the cleaning function We used statistical analysis to plot the correlations between performance increase and concept variance change With this data we can conclusively recommend the implementation of bristle lengthening and down force increase for a simple inexpensive and efficacious redesign After performing FMEA we found the various modes of failure and ways to lessen the chances of them happening By considering DFM DFA and DFE we identified other ways to improve the Grillbot such as better manufacturing assembly and use Finally based on our experimental results we built a final prototype This functional Alpha prototype represents the semester long body of work we put towards the Grillbot 14 APLICACI N DE LA METODOLOG A DE DISE O MEC NICO PARA LA INGENIERIA INVERSA Y RE DISE O DE UN ROBOT DE LIMPIEZA DE LA PARRILLA Autor Reina G mez Acebo Mar a Director Rylander Christopher Instituci n Colaboradora The University of Texas at Austin RESUMEN DEL PROYECTO Si alguna delicia gastron mica podr a ser competencia a la tarta de manzana Americana s lo podr a ser la barbacoa Barbacoa ha sido un elemento b sico de la cultura americana desde la poca colonial e
107. ht and long bristles We also decided to carry out the whole experiment twice for accuracy Building the Prototype First we made the brushes out of PVC as we had easy access to it and it would be easy to machine We made two brushes both the same length but a bit longer than the original brushes to be able to fit an aluminum adapter that would attach them to the motor We drilled holes in them where we inserted the bristles which were made of copper wire We used copper wire as it has similar material properties to the original brass bristles Lastly we used hot glue to affix the bristles in place While one of the brushes had constant bristle length same length as the original ones the half of the bristles of the other brush was longer than the other half We had to make the brushes twice because the first time the bristles interfered in the center since the columns of holes were aligned Therefore when we made them again we had to make sure that the holes had a certain offset to prevent this problem from happening These prototype brushes are shown in Appendix AJ The complete assembly of the experiment model can be seen in Appendix AK We made the whole test stand out of wood because it was easy to use and cut and strong enough to carry out the experiment Most parts were glued together and some were reinforced with a few screws We wanted the rod to be equivalent to a grill grate We measured the diameters of about 20 grills to determin
108. ice are adding a water hose at the bottom of the Grillbot or have several nozzles sticking out of the bottom of it However we would need pumps and engines to adopt this method 155 Redesign Avenue Improve Cleaning Types of Energy gt MEE Ri Acoustic Sub Functions Principles Principles Principles Principles Principles Transmit RME Brush motor shaft E Convert RME to TME Chebyshev linkage Hockens Linkage borne Import Fluid Electric Pump Jet Pump Flammable Chemical Bezene Dispense soap from Brushwhcel radial Electric Pump Three Phase W22 JM Type Pump axial Flammable Chemical Propane Dispense water from Brushwhecl radial Pump Variety Dispense soap from Brushwheel axial Dispense water from Brushwheel axial Convert EE to ThE Induction Heating i Stca Radiowave Resistance Heating Regulate friction 1133 ter Chang Voltage Brush Steel Potentiometer Challe of single of incl Brush Rubber Heavier materials for the device Brush Pattern Zig Zag Brush Pattern Different Length Brush Pattern Aligned in a straight line Clamp the grille Convert EE to Vibrational E Vibration Ultrasonic Bathtub Ultrasonic Cleaning MEN Pf radial side of brush axial ends of brush RME Rotational Mechanical Energy TME Translational Mechanical Energy EE Electrical Energy ThE Thermal Energy Virbrational E Vibrational E AC Alternative Curr
109. iciency for an entire range of usage conditions 9 10 25 34 Interconnecting available flows of energy and materials within the product and between the product and its environment 9 21 35 sts ota anche e 9 25 31 36 Using feedback mechanisms to mdicate how much energy or water 15 being consumed 5 37 Incorporating intuitive controls for resource saving features 8 10 38 25 the p 42 Improving aesthetics and functionality to ensure the aesthetic life is equal to the technical life 5 7 25 29 30 43 Ensuring minimal maintenance and minimizing failure modes im the product and its components 6 9 30 32 de cum c er eee wear 4 4 45 Indicating on the product which parts are to be cleaned maintained in a specific way 7 25 46 Making wear detectable 4 7 25 47 Allowing easy repair and upgrading especially for components that experience rapid change 4 24 48 Requiring few service and inspection tools 4 49 testing of components 4 50 z epetitive dis and re assemb F Enable disassembly separation and purification by 21 51 Indicating on the product how it should be opened and make access points obvious 5 7 25 28 31 52 Ensuring that joints and fasteners are easily accessible 28 31 32 53 Maintaining stabibty and part placement during disassembly 4 31 54 Minimizing the number and variety of joining el
110. il throughout their lifetime and affect the functionality of the product The components are the main circuit the power button the brush motor shaft the battery and the battery charger port If one of the components fails our device will not be able to function properly We could have considered the screws the casing and the sub circuit however we determined that they are not crucial components to cause a disruption in the functioning of the machine if they failed individually Next we identified the modes of failure for each of the components and the causes of failure Also we listed what will happen after failure For the main circuit the possible failure modes can be overheat and soldering failure When there is a faulty electrical connection in the circuit the circuit could burn Also when the solder gets weakened and it is not noticed in the earlier stage the solder could fail If the main circuit fails then it will not be able to regulate electrical energy and work inefficiently Furthermore the device could fail to operate For the power button we thought of the modes of failure based on its material The rubber can be easily torn and could be worn out after it is used many times or improperly Then the users will have trouble starting the device It does not directly affect the functionality of the device but 1t would not satisfy the users expectations For the motors we stated four failure modes stator stall come loose and
111. ill bend 0 1 Cm for eve 400 paper chips a paper chp is abat 40 172 Fa rec ie F 1009 5 8 N hs EX Y 2 AN Soon m jt 0 02m Tre mass of the Gibo s approx meleiy Sto kks assume ls of tre weight 5S rasfered 4o a buste 4 ch Ae mueca OF BASES N ONAA Ww SueFACE The brisHes bend F 4 9 8 40N Ex 00 Ax gt cra Zcm TMS an wwreaistic deflechon since tre brisHes are abal acm wmch Sup esto Non lineardy wder lar e deflech ons However for mede Purposes ths kt xmv Masne 209 5o oo 2w 4 0 02ta W fl tr yr 2318 mjs Potahona Velocity of BUH gt Y we dable the mass F 20N 500 X x 40n 1 50 MY n04m Y 32 m s we dable the yeloaty The aer tre wiaty He greater He fore Veka values are very hoy beaut Of tr near deflecton 173 pn M Y M M M gt Increasing the dawn f rce 0 uwately rest in kvger Aichonal forces Gnd lorogr whiplash veloches Bath of hese facras ove advmtageous in remomg sediment that have high Internndecule ACES 2 Current Brush Faut VIEW TOP VIEW Afferent lengths __ _ akuan of danna area of awent Gross 2 area of ore brise shard 7 26mm 0055 o biste ads mn me gap of bushes c 0
112. inar la acumulaci n de part culas de una parrilla calentada sin la necesidad de esfuerzo del usuario La m quina hace el trabajo por medio de tres motores el ctricos de inducci n separados stos imparten un par a los ejes que tienen cerdas de alambre incrustados Los motores giran seg n un algoritmo programado en el controlador que general movimiento alterna de forma aleatoria Los cepillos giratorios son desmontables y est n disponibles para su compra con cerdas de acero o de cobre El Grillbot trabaja en tres configuraciones programadas 10 minutos 20 minutos y 30 minutos Estos tres valores pretenden ofrecer todos los niveles de extracci n de mugre La alimentaci n de la Grillbot proviene de una fuente de bater a interna de manera que pueda ser portable El Grillbot nominalmente puede funcionar durante cinco ciclos de 30 minutos con una sola carga de la bater a La bater a se recarga despu s con un adaptador de alimentaci n de CA que est conectado a un puerto hembra en el Grillbot Una de las principales razones por las que el Grillbot era una buena opci n para el an lisis preliminar de mercado es que varias fuentes contaban con opiniones de los clientes que dec an que les gustaba la idea pero ten an quejas sobre su funcionamiento Por ello se cre a que se podr an hacer muchas mejoras que permitir a al Grillbot soportar ambientes m s c lidos ser m s f cil ergon micamente y ser capaz de quitar y despegar m s sedime
113. index htm Consumer Reports publishes reviews and comparisons of consumer products and services based on results and reporting from its survey research center and in house testing laboratory We found an article based on the Grillbot where they talk about their personal experience with the product and give both positive and negative feedback Because the reports are based on subjective experiences this article is not entirely credible The information gathered is qualitative and subject to interpretation However Consumer Reports is widely known among the market to test and report on new technology Therefore it is important to know what the report on our product contains and how it can be factored into our customer needs analysis This source provides customer opinions on the Grillbot from several perspectives and gives us ideas on what consumers want from the product It is different from the customer reviews on Amazon com because this is an article written by one person describing what they felt was good and bad about the product which we feel adds perspective to the customer needs 3 Grilling product reviews archives GrillJunkie Addiction to grilling 2014 June 25 Retrieved February 16 2015 from http grilljunkieguy com category grilling product reviews grilling product reviews grilling product reviews page 2 Grill Junkie s blog posts provide Grilling and BBQ product reviews through their Grilling Product Review GPR rati
114. ing from the motor We can figure out causes of noise from reading this In addition it tells you the materials of each part so it is easy to figure out what we need to change and improve For example many customers complained about how expansive it is We could research costs of materials that were used and replace them to cheaper materials that have similar properties and functions 4 Marsden A K Lambertson M C and Renzo D P 2014 U S Patent No 8844087 Cleveland OH The Sherwin Williams Company The US patent issued to Marsden Lambertson and Renzo is extremely specified with a one finger separator This invention can be used to clean variety of objects such as surface of desk bath tub and sink This patent includes pictures of different point of views of this invention top view side views bottom view section view perspective view and assembly views Each of part is labeled on the pictures and explained in detail in the patent This invention is composed of a brush body having a proximal end a distal end and a handle on the proximal end of the brush body The wire brush is detachable from the body The wire brush is a key feature of the design of the Grillbot The condition of wire brush directly affects the effectiveness of our project If the user did not clean the grill from last time use crumbles would have been hardened and stick onto the grill and it is harder to clean with the brush This wire brush is d
115. ing minutes with a sponge effectiveness Almost dropped it Easy to grasp Moves slower to clean one area ata time 1 Grilling experience level 7 Easy to operate figure out Moves around too much n a Value 1 Overall rating 3 0 Sounds like a trapped animal like if you tried to grill a live squirrel Could be heavier needs more weight to properly clean Could use a handle Looks good I would never buy this it only takes like More forceful scrubbing action Easy to grasp Aesthetically pleasing Add value by increasing effectiveness m 0 13 14 15 5 minutes to clean by hand Grilling experience level 5 c 1 2 3 ON 110 Chase Stephen Easy to hold 4 Easy to clean out 7 Easy to operate figure Overall rating I like that it is effortless and effective Set it down on the ground hard and bent some brushes Battery life is great It s been cleaning for about an hour and still has more than half the battery life Taking off the brushes gets your hands dirty I don t like that it s loud and very expensive I wish it were self Easy to clean or self cleaning cleaning Grilling experience level as 081111 3 woe _ 4 Hemem 3 TT s 707777 4 3 7 Easy to operate figure out Dm a Does my cleaning job for me I like that Price is
116. ing after 10 i and quickly minutes of use Noisy as all get out Rubber edges to 15 Make quer Make quieter less banging QN minimize banging against sides Grilling experience 5 level 1 n a 108 Sean John Easy to clean 4 6 7 Easy to operate figure 5 out s ww TT Sounds like a 11 More effective at cleaning Would rather use a hand brush Easy to grasp Could be easier to hold adding a handle More value for the money shouldn t affect Make quieter and more affordable High scrubbing force performance Too expensive 10 for a brush of 130 for this I like that it creates less work for the user Oo m N 14 5 Too loud and expensive 1 Needs more weight Nick Grilling experience level 89811 NENNEN 0898111 cen 4 7 Easy to operate figure out DW l3l aspect It cleans even on a hot erill I didn t have to 0P l resistance wait for it to cool 12 Easy to use and disassemble 13 Don t like the noise 4 I could clean grill better for cheaper 16 1 a Intuitive operation Add value by increasing effectiveness 5 c 5 e 109 Easy to hold 5 5 O e Beedem 3 EN NN out 3 we A Aesthetically pleasing 10 cool 11 I could do a better job Add value by cleaning the grill in 2 increas
117. ing our customer interviews This information will also help us understand the customer needs by understanding the primary customer From our research we have found the main competitor of the Grillbot to be the manual wire brush Consumer Reports 2014 The Grillbot contrasts with the wire brush in that it requires very little manual effort from the consumer The inventor of the product wanted to make cleaning the grill automatic so that users never felt burdened by the cleaning process However from consumer reviews we have discovered that by automating the scrubbing process you sacrifice in other areas of enjoyment For example many Amazon reviews have described the sound the Grillbot makes as releasing a wild animal inside Customer Reviews Amazon 2015 Many complaints have emerged from this loud banging sound coming from the grill Another complaint concerns the efficacy of the product itself In fact many people note that no matter how long they run the Grillbot for there is still a need to use the manual brush after the timed cleaning cycle Finally the reviews from Amazon also point to a decay in the brush integrity after a short period of use Namely reviews comment on the loss of wire bundles from the rotator brush and of rapid decline in battery performance Customer Reviews Amazon 2015 By having an idea of the main product defects we will be able to address complaints through our interview selection and design process
118. iny bristle mounted at the tip You just grab the handle and brush your teeth with it Since people eat food every day it is easy to get food residue and plaque between teeth and gums Panagakos amp Migliorati 2014 One of the factors that help getting rid of food residue is having a different pattern of bristles Some toothbrushes bristles feature a cup shape for cleaning around the teeth and a diagonal pattern of bristles to clean the sides of the teeth and along the gum Wavy or V shape patterns are used to give the bristles a better contact with the areas around the adjacent tooth surfaces Factors n d Different patterns of toothbrushes inspired us to have different shapes of bristles If we have brushes with various lengths our device would be able to get rid of food residue on the edges of grill Manual n d A WHOLE MOUTH CLEAN Experience ZEN _ g am Qe Soft textured tongue cleaner Raised cleaning tip bristles Extended pointed outer bristle tufts Tightly packed centre bristles Polishing cups made of soft rubber 152 Ultrasonic Glass Cleaner Ultrasonic glass cleaning uses high frequency sound waves to remove many types of contaminants from parts immersed in aqueous media This could get rid of contaminants such as dirt oil grease buffing polishing compounds and mold release agents Ultrasonic n d Ultrasonic cleaning could get rid of dirt oil and grease which we want
119. is more efficient in cleaning we changed the diameter of brush wheel to 53 98 mm from 47 625 mm The diameter is defined as the longest diameter for the brush wheel and the bristles combined In addition we changed the bristle material to SS 306 We also increased the mass by 6 5 oz 184 g As aresult the top shell weighs 256 28 and lower shell weights 361 2 g As we discussed in DFA it is good to combine the handles with the upper shell because it will make disassembling and assembling the product easier and will prevent component loss We named the combined component as upper shell Also we decided to combine bottom pads and the bottom shell together This will also allow the users to assemble the product easily without changing the function From these changes we reduced the total number of components from 57 to 44 The screws that will be used for the sub circuit and the main circuit are named circuit screws The screws that are used for the lower shell and top shell motor and power cord are named regular screws By doing this the types of screws have been reduced from 8 types to 3 types To determine the dimension and weight of particular types of screws we averaged the values of combined screws Since we are using circuit screws for the main circuit and the sub circuit we wanted to create a screw that can be used for both places We averaged the values of combined screws to resolve this problem As we mentioned in DFA section we added paint t
120. izes alternating motion The rotating brushes are removable and available for purchase with either steel or copper bristles The Grillbot works on three timed settings 10 minutes 20 minutes and 30 minutes These three settings are intended to accommodate all levels of grime removal The power from the Grillbot comes from an internal battery source so that it can function portably The Grillbot can nominally run for five 30 minute cycles on one battery charge The battery is then recharged from an AC power adapter that 1s plugged into a female port on the Grillbot One of the primary reasons the Grillbot was a good selection for preliminary market analysis 1s that the customer reviews from several sources loved the idea but had complaints on its operation It was believed that many improvements could be made that would allow the Grillbot to endure hotter environments be more user ergonomic and remove more sediment Therefore this project focused on engineering solutions that would make the Grillbot a better machine It was divided in three different phases task clarification and reverse engineering conceptual re design and parametric re design During Phase I we interviewed customers about their experiences with the Grillbot and analyzed their responses We conducted reverse engineering of the product following three basic steps prediction teardown and analysis In the prediction step we created a black box model a hypothesized function
121. l of food ware articles such as a multilayer stick resistant and ceramic coating This invention has a metal food ware article that has an inner food contacting surface and an outer surface bonding layer deposited on the food contacting surface It talks about how each stick resistant layer is processed and what kinds of equipment are used in order to process it This contains the kinds of materials that are used for each of the layers They have done experiments on this invention to see if it resists food from sticking onto its surface The experiments were an egg frying test and a rice cooking test Molly Mo Hui Ge invented this stick resistant multi layer ceramic coating Since she is the only inventor and it is for her benefit we would say it 1s a little bit biased This is a relevant source because when Grillbot is cleaning the grill the food will stick to the wire brush We could use her idea of a stick resistant layer and process it so that it minimizes the effort to wash the wire brush The coating is not only stick resistant but scratch resistant thermally stable and corrosion resistant Therefore it could apply to the bottom part of Grillbot Scratch resistant and corrosion resistant functions could help maintain the Grillbot better and for a longer period of time Also the corrosion resistant layer would prevent the wire brush from getting rusty and leaving particles on a grill which could be hazardous to humans 3 Woods Etha
122. l speed with the various bristle lengths TIPS result can be found in Appendix AC Concept Variants We selected the five concept variants Appx AD for the functional redesign avenue based on mind maps 6 3 5 sessions the morphological matrix the TIPS and background analogies We selected the five concepts for industrial redesign avenue based on mind maps and 6 3 5s We also considered general physical limitations cost complexity performance and how much each design meets customer needs to narrow our focus and eliminate unrealistic avenues Concept Variants for Functional Redesign The particular customer complains about the cleaning performance of the product concerned the lack of penetration ability to remove grime from the spaces in between the parallel grill bars and the inability to remove hardened oils that have large intermolecular forces binding them to the surface The first functional redesign concept variant is to increase the weight of the Grillbot We considered this equation Frriction ux mass gravity As you increase the mass of the device the friction will get larger Increasing friction between the grill and the device will pull off more dirt from the grill Therefore it will clean better Additionally we reasoned that by increasing the down force we would also increase the depth of penetration which would increase customer satisfaction To increase the mass we could make the device body thicker add additional mat
123. l to grillbot 2 Zine plated steel OEM Turning Plating 10 4 88 9 91 3 52 OME Original Equipment Manufacturer EE Electrical Energy RME Rotational Mechanical Energy D Diameter Ni Nickel Cu Copper LCD Liquid Crystal Displays E External Parts Linternal Parts 5 525 Bill of Materials Appendix O Appendix P Exploded Views 122 Label screw Label washer Label Handle Upper shell Handle upper shell attachment screw Y Power button cover 8 in 21 cm ruler for scale I Doghouse clip broken Battery cushion pad 2 Battery cushion pad 1 Lower shell upper shell attachment screw 6 Bottom pad 1 Lower shell Battery Bottom pad screw 1 x2 Pp Lower shell upper shell attachment screw 1 Motor 1 Brush motor shaft screw 1 Motor screws 1 x2 Brush motor shaft 1 Brush wheel 3 Brush motor shaft 3 Motor screws 3 x2 Brush wheel 1 Lower shell upper shell attachment screw 5 1 Brush motor shaft screw 3 Motor 3 A Bottom pad 3 END Epoxy Bottom pad screw 3 x2 __ Ze Lower shell upper shell attachment screw 2 Bottom pad screw 2 x2 Bottom pad 2 Lower shell upper shell attachment screw 4 Motor screws 2 x2 Brush wheel 2 Motor 2 Lower shell upper shell attachment screw 3 Brush motor shaft screw 2 Brush motor shaft 2 Scale 1
124. ll Clean the grill 66 4 TC 895 AB BLACK Brass Plastic injection molding Wires OEM Cutting Assembly to the brush 67 4 474 25 6 4 Battery 1 Import stored EE to the Maincircuit 110 2 Lithium Ion OEM 34 36 3 31 5 Battery cushion pads 2 Provides soft support for battery 0 4 Heat resistant foam Formed dyed slabstock process and cut 69 32 1 2 45 13 Thermocouple and epoxy 0 6 1 Thermocouple 1 Detect the temperature OEM Welding 2 Epoxy 1 Fastens thermocouple to bottom of lower shell Epoxy Mixed and applied 5 Screws Nominal D Body D Length total Length head 1 Bottom pad screw 6 Fastens pads of lower shell to lower shell 0 7 Zinc plated screws OEM Turning Plating 6 49 3 83 10 18 2 57 2 Lower shell and top shell screw 6 Attaches lower shell to top shell 1 5714286 Zinc plated screws OEM Turning Plating 6 67 3 89 13 74 4 18 3 Power cord screw 1 Attaches power port to top shell 0 1 Zinc plated screws OEM Turning Plating 72 234 9 42 1 5 4 Motor screw 6 Attaches motors to lower shell 0 3666667 Zinc plated screws OEM Turning Plating 5 43 2 87 7 67 1 49 5 Shaft screws 3 Attaches brush shaft to motor spindle 0 4 Zinc plated screws OEM Turning Plating 6 63 195 10 1 95 6 Subcircuit screws Attaches subcircuit board to top shell 0 15 Zine plated screws OEM Turning Plating 3 53 2 27 6 5 1 48 7 Maincircuit screws 4 Attaches main circuit board to lower shell 2 5 Zinc plated screws OEM Turning Plating 3 95 2 66 9 33 1 94 8 Label screw 1 Attaches labe
125. mico o en el estilo del producto En la fase I se formularon cinco avenidas de redise o incorporar materiales de reducci n de ruido mejorar el material de las cerdas del cepillo aumentar la potencia del motor mejorar el mango y a adir peso La Casa de Calidad el an lisis de las necesidades de los clientes y la viabilidad fueron considerados para finalizar las avenidas de redise o para el cambio funcional y el cambio industrial Cambio funcional Centrandonos en la Casa de Calidad de la Fase I la eficacia de la limpieza obtuvo una calificaci n alta en la columna de la importancia relativa Durante la entrevista uno de los clientes comentaron que si el Grillbot pesara mas limpiaria mejor Esto nos dice que el cliente quiere que el Grillbot limpie mejor Incluso despu s del proceso largo de limpieza del Grillbot la suciedad a n permanec a en los bordes de las rejillas porque los cepillos no est n dise ados para limpiarlos Limpiar la parrilla minuciosamente es extremadamente importante porque cuando los residuos de comida no se limpian bien y se mantienen en la parrilla se quemar n cuando los clientes vuelvan a utilizar la parrilla de nuevo m s tarde Cuando se quema la comida se producen sustancias cancer genas llamadas hidrocarburos arom ticos polic clicos HAP Como resultado decidimos mejorar la limpieza como nuestro avenida de redise o funcional Cambio Industrial Bas ndonos en las entrevistas los clientes
126. mment TE The of USTe HAD TE Cleay Easv to operate figure out 1 2 3 4 5 comments Si NGOLE RUTA Sed Value 130 Y i 8 M 3 comment j W vea Gwy qus Tos Cey E pe va ms An ple Overall rating E s D d pee SS SSS RR CS Whar ao vou tike about the GriliBot CELE CUUENES S What do vou NOT like about the GrillBot cx pe NSE Y NVISE What would vou change mM Me IT CSE Ho U 5 CALEA pe qu Would vou buy it Why why not 1 NG Te ERs E Do BE u a Banst E wnat would you Day tor m 30 95 Name Lp aa Zare vour geruime experience ievei i 2 3 t ES AS Appearance i 2 3 5 P 3 Comments No Noise i E 25 5 Comments Made On lok Mo 28 nen Clean Effectiveness 1 2 E ANS comment Easy to hold 1 2 3 y s 5 Comments Easy to clean the GrillBot i QD 2 s Comment x A litle herd do ar besh 8S of ani DUCK OV Y m Easy to operate figure out 2 3 5 5 Lommentis Value 130 i d 3 4 5 Comment 1 Too EX PIAS D j de Would n Puy thet Mack Se O Oe ee ee ann nn nn 1 A nn nn nn nn mmm aaa Whar ao vou like about the GniiBot Cleaned the Yew What do vou NOT like about the GrillBot RAIL What would vou change T woul Try Cu
127. mparison Function Structure 1 Entire Reverse Engineering Update Specification Sheet and problem 3 2 15 3 6 15 100 statement Phase 2 To do List 3 9 15 3 9 15 0 Gantt Chart 3 9 15 3 9 15 0 Select Adaptive Avenues 3 11 15 3 15 15 0 Brainstorming 3 11 15 3 15 15 0 Mind Maps 3 16 15 3 20 15 0 6 3 5 3 16 15 3 22 15 0 Design Change Concept 0 3 16 15 3 22 15 Functional Re design Concept Variants 3 23 15 3 28 15 o Industrial Design Shift Concept Variants a 6 Pugh Chart 3 30 15 4 2 15 0 Order of Magnitude 3 30 15 4 2 15 0 Phase 3 To do List 4 6 15 4 6 15 0 Gantt Chart 4 6 15 4 6 15 0 Develop Experimental Model 4 6 15 4 11 15 Experimentation 4 6 15 4 12 15 0 Back of the Envelope 4 13 15 4 16 15 0 FMEA 4 15 15 4 19 15 0 Design for Assembly 4 20 15 4 24 15 0 Design for Environment 4 20 15 4 24 15 0 85 Preliminary Drawings 86 Appendix B Patent cover pages ISS ASA 1 Putent Number 5 839 454 5 Date of Patent Nov 24 1998 447 As KAGO Falla nal 34 X 4 182064 33090 Federali eb aL cain 134 202 X nA GO Rel 134 57 A Primary Exanmuuer Phmhp R Coe Attorney Agent or Pirm Melale de Slavin 127 ABSTRACT The instant iverica 15 an automatic detergent cispenser bor residentzal dishwashers allowing transfer of Haud frons a store
128. n Maintenenace and product cleaning time minutes per use ase of use Battery life minutes leaning abili ojo Net total urchase cost leaning time minutes evelopment risk of OEMs and vendors to source parts urability months of operation Maintenenace and product cleaning time minutes per use ase of use Battery life minutes leaning abili otal mizlolojo SAR m o Net total urchase cost S leaning time minutes evelopment risk 4 of OEMs and vendors to source parts urability months of operation Maintenenace and product cleaning time minutes per use ase of use Battery life minutes leaning ability otal otal et total urchase cost leaning time minutes evelopment risk of OEMs and vendors to source parts urability months of operation Maintenenace and product cleaning time minutes per use ase of use attery life minutes leaning abili otal otal ri 0 Purchase cost leaning time minutes evelopment risk of OEMs and vendors to source parts urability months of operation Maintenenace and product cleaning time minutes per use ase of use Battery life minutes leaning abili Net total Sum of Net Totals 187 Appendix AI To Do List and Gantt chart for Phase III Complete Complete Complete Complete Complete Complete Complete Complete Complete Make the List Distribute work Make the chart Plan Det
129. n 2012 U S Patent No WO2013082046 A2 Washington DC U S Patent and Trademark Office The International patent issued to Ethan Woods is for cleaning a surface such as a barbeque grill The hollow enclosure has a plurality of motors where each has a rotational shaft selectively fixable with a rotatable brush The author talks about the functions of each part and how this invention is working and changing direction of the grill cleaner The enclosure of Grillbot contains a power source and a circuit The circuit is used to change the direction of the cleaner The circuit adapted for connecting power to each of the motors for a preset period of time upon actuation of an electrical switch connected thereto As a result the circuit runs each motor that moves Grillbot to a certain direction and it eventually turns around due to the alternating directions of the motors 78 This patent is written by Ethan Woods He created a company called Grillbot LLC to sell and published this patent therefore this patent tends to be biased He would write only good parts of Grillbot This patent is useful for our project because this is a patent of our product It is a good source that explains the basic mechanisms of movement Also this talks about the details of each part such as brushes battery power source and circuit It thoroughly describes how each part 1s connected to motors Customers complain that it makes too much noise and this noise is com
130. n oh Moke iy a lite qe anh eos ar to dam Pres Off Would vou buy it Why whv not N Mt Mee Ves WE Geol not wnat wouia you pay tor S50 96 Name e Bir is mM N Lal dace vour eriiiing experience ievei Appearance 1 2 3 gt Lommenis Noise ERI 2 3 4 5 Lomments sna ew aw HA A box Effectiveness Comment Cv er d Ha bu ool L f bu Tee LIA Cross bars peleks Abre 5 Easv to hold m 2 1 2 3 4 ES comments gt Easv to clean the GrillBot comment ns hrisHes Such Easv to operate figure out 1 2 3 5 Comments tad RF A Value 130 Clu 2 3 4 5 Comment ett Vb Overall rating i 2 p 4 5 Wha do vou like about the GriliBot yas ole ES Gan efte hi ve gee ces aller US What do vou NOT like about the GrillBot Mois s all eut f What would vou change robber B d minimize hangin side gt 7 Would vou buy it Whv whv not o ASC lec laziness 1 what woula you vay for st 40 56 97 7000 Ni tJi Un mM Rx Ln 6 3 0 a Name nh ee vour eriume experience evel Appearance Lommenis Noise Comments Effectiveness Comments Easv to hold Comments Easv to clean the GrillBot Comments Easv to operate figure o
131. n the Grillbot are mechatronically controlled the textbook by Karnopp and Margolis System dyanamics modeling will prove a valuable resource in understanding current design so that we may produce a better redesign This textbook is a very credible source because it was written by three mechanical engineering professors at the University of California The credibility results from years of control system experience in industry as well as in academic pursuits The powertrain of the Grillbot is dependent on the transduction of electrical energy to mechanical energy The battery recharges using 120V AC power from a standard wall outlet By using the motor specs that deliver a specified power output and the battery life we can calculate 76 using energy flow diagrams the torque being applied to the grill surface and the transverse speed of the Grillbot By developing a dynamic model for the system we can pinpoint negative parameters and vary them with our model to achieve a desired output This is useful for our analysis because we know the product s limitations and we know how to change them for future design criteria Therefore this textbook is relevant to our analysis because it will assist us in analyzing the speed and direction of the motors once we are able to dissect the system and observe the controller unit Patents 1 Wichert et al 2015 U S Patent No 8 947 024 Washington DC U S Patent and Trademark Office The US pa
132. ness coefficient k We approximated the k value experimentally by attaching a container to a sample spindle which was fixed at one end First we measured the bending from the container which was less than mm We then measured the amount of bending that resulted from adding 100 paper clips to the container and found that the bending was approximately 2mm The assumptions made in finding the k value is that mass has a linear relationship to displacement bending by a factor of k g We also approximate the displacement by only considering the vertical displacement and disregard the horizontal change Although this linear approximation only applies to small 181 displacements calculating it will help to show that increasing the downforce increases the whiplash velocity and as a result also increases the impact force to each particle The next critical assumption made is that energy 1s conserved Therefore the assumption implies that there 1s no friction from air resistance or from contact with the grille By making this assumption we are able to say that the potential energy stored as a result of the bending of the brushes converts entirely to kinetic energy at the point of largest velocity the resting x coordinate of the brush The following assumptions are made when relating velocity to displacement in the form of e Energy is conserved e Energy has a constant exponential relationship with regards to energy flows e Gravitational forces a
133. ng multiple functions into single parts Iredale 194 2 Modularize multiple parts into single subassemblies Crow 1988 3 Assemble in open space not in confined spaces never bury important components or components that require maintenance Tipping 1965 4 Make parts such that it is easy to identify how they should be oriented for insertion Tipping 1965 5 Standardize to reduce part variety Tipping 1965 6 Maximize part symmetry Iredale 1964 Paterson 1965 7 Design in geometric or weight polar properties if nonsymmetric Tipping 1965 8 Eliminate tangly parts Iredalte 1964 Tipping 1965 9 Color code parts that are different but shaped similarly 10 Prevent nesting of parts Iredale 1964 Tipping 1965 11 Provide orienting features on nonsymmetries Iredale 1964 Tipping 1965 12 Design the mating features for easy insertion Iredale 1964 Tipping 1965 Daldwin 1966 13 Provide alignment features Baldwin 1966 14 Insert new parts into an assembly from above Tipping 1965 15 Insert from the same direction or very few Never require the assembly to be turned over Tipping 1965 16 Eliminate fasteners Iredale 1964 17 Place fasteners away from obstructions 18 Deep channels should be sufficiently wide to provide access to fastening tools No channel is best 19 Providing flats for uniform fastening and fastening ease 20 Proper spacing ensures allowance for a fastening tool Telenkom et al 2
134. ng system They review and rate grilling products by providing a 6 category written review and then assigning a 1 5 scaled FirePot rating to the product In 2014 they posted a GPR for the Grillbot Here not only do they talk about the product itself its features and pros and cons but they also discuss all of the different grilling surfaces as well as traditional grill surface cleaning tools 74 This source is useful to us because it informs us about the different grill cleaning methods there are already available in the market It gives us an idea of what customers have and use at the moment and therefore what will be expected of the Grillbot if it is to replace all of these Although useful for reference this source cannot be counted as entirely credible For one the article has no author other than Grill Junkie Boy Additionally the format of the website appears very unprofessional There are pop up advertisements over a large portion of the screen and the information presented seems haphazardly strewn However because a part of our demographic will frequent this site to gather information it is relevant to our research 4 Member locator n d Retrieved February 16 2015 from http www hpba org consumers barbecue grilling facts and figures This online article published by the Hearth Patio amp Barbeque Association highlights the results of a biennial study conducted by the organization The study addresses the
135. nto de la parrilla Por lo tanto este proyecto se centr en buscar soluciones ingenieriles que har an del Grillbot una m quina mejor Est dividido en tres fases diferentes clarificaci n de tareas e ingenier a inversa redise o conceptual y redise o param trico Durante la Fase I entrevistamos a los clientes acerca de sus experiencias con el Grillbot y analizamos sus respuestas Se llev a cabo la ingenier a inversa del producto siguiendo tres pasos b sicos predicci n desmontaje y an lisis En la etapa de predicci n creamos un modelo de recuadro negro una hip tesis de la estructura funcional y un boceto de predicci n de la secci n transversal Esto era para ampliar nuestros pensamientos e imaginaci n del producto y as aumentar las posibilidades de redise arlo En el paso de desmontaje llegamos a ver el interior real 16 del producto y aprender c mo funciona Se realiz entre otras cosas el informe de datos de los materiales y la vista de despiece Por ltimo la etapa de an lisis se compone de la estructura funcional real y la matriz funci n de componentes Para la Fase II se nos pidi explorar posibles redise os aplicables al Grillbot Un redise o de adaptaci n deb a alterar significativamente la funcionalidad del producto y otro redise o adaptativo deb a incorporar un importante cambio de dise o industrial al producto El cambio de dise o industrial deb a influir en la est tica aspecto ergon
136. o combine the bottom shell with the bottom pads If they were mounted on the bottom shell it would be easier for the users to assemble them The bottom shell and the bottom pads are made out of the same material and there is not a particular advantage the users get from having them separated Telenkom et al 2008 Screws Eight different screws are used for our product Some of the components have the same number of screws and look similar therefore the users might get confused when trying to distinguish which screws to use We can use DFA guideline 9 which is color code parts that are different but shaped similarly If we use different colors or label them then users would recognize them easily The other method to reduce the types of screws could be using the same type of screws on the components This is followed by guideline 5 standardized to reduce part variety For example we could use the same type of screws for the sub circuit and the main circuit Then we can use the same screw for the lower shell and top shell screw motor screws and power cord 66 screws Since the shaft screws need to be smaller to connect the motor and the shaft we want to keep that type of screw It is shown in Appendix AQ 2 Telenkom et al 2008 As a result the number of components can be reduced from 56 to 42 components Also the types of screws can be reduced from 8 to 3 types It will take less time to assemble or disassemble the pro
137. o the finish so that the users can distinguish each screws easily Updated bill of materials can be found in Appendix AO 69 Final prototype For our final prototype we embodied the optimal design variable values that we found from experimentation From the experiment data we found the brush that had various lengths bristles to have the best response Although the results showed that the trial with increased bristle length and increased weight cleaned the grill more efficiently we focused on making the brush for our prototype If we were to increase the weight however we could make the casing thicker We 3D printed the body of the brush with holes of 0 25 inches These are slightly larger than the previous prototype s holes so that we could fit in more copper wire Similar to the initial prototype the bristles were secured with hot glue to prevent them from sliding or falling off We then attached the brush directly to the motor shaft by installing a setscrew in a radial hole at the proximal location Although we 3D printed this hole it came out too small We had to enlarge it by drilling it a bit so that the hole would fit the motor s shaft The final prototype is shown in Appendix AS 70 CONCLUSION Through all of the experimentation analysis design and prototyping we have made a Grillbot that cleans better than before During experimentation and the subsequent parametric analysis we proved that both longer bristles and incr
138. o thoroughly clean Therefore we chose the third place finisher increasing the weight as our second parametric interest This cleans better while also being low cost and simple to implement Once we had those factors in mind we had to think about the best responses and how to test them Since we are trying to improve cleaning our response variables are depth of penetration of the bristles and the amount of dye removed These responses will tell us what features can clean the edges of the grill better and how much it can clean The first one refers to how far the bristles reach on the grill grates while the second response measures how much food residue is actually removed We thought that testing the response variable of depth of penetration on a real grill grate would be very difficult so we decided to simplify it by building a frame that would carry out this test 57 Experimental Model After some group brainstorming we came up with the following experiment We applied Prussian blue dye on a rod placed under the prototype brush and run it by attaching the brush to a motor We chose Prussian blue dye because it 15 a viscous pigment that resembles the actual grease on a grill Also as the dye is blue and we would be measuring the results optically 1t would make it easier to see and compare We carried out four different trials as we had two factors no weight and short bristles no weight and variable bristles weight and short bristles weig
139. of the same plastic material to improve the product s simplicity The plastic will be recycled and made to be heat resistant This is according to guideline 7 Prevent hazardous material release Following DFE guidelines 10 and 28 we will prevent release of hazardous substances and implement fail safes against material loss Our new brushes will retain their brass bristles much better than the original Grillbot We will do this by threading the bristles all the way through the product instead of press fitting a shallow section of bristle During initial testing several bristles fell out These bristles if ingested could wreak havoc on the human digestive system and in some cases lead to death In addition to holding onto those bristles we will add bright colors to the holes so that the user will see if a bristle has been lost 68 Maintaining part placement Lastly we will utilize the DFE guideline 53 by maintaining the placement of the electric motors during disassembly Currently the motors are free to fall out of the shell once unscrewed We will add plastic retainers to the sides of the motor so that the user snaps them in and out of the chassis Those plastic snaps will be molded in the same step as the bottom shell Revised Bill of Materials After we redesigned our product we made a change to the bill of materials that we created after disassembling the product Since we concluded that using alternating lengths of bristles
140. oporte digital para su incorporaci n a una base de datos electr nica incluyendo el derecho de reproducir y almacenar la obra en Especificar si es una tesis doctoral proyecto fin de carrera proyecto fin de M ster o cualquier otro trabajo que deba ser objeto de evaluaci n acad mica servidores a los efectos de garantizar su seguridad conservaci n y preservar el formato c Comunicarla y ponerla a disposici n del p blico a trav s de un archivo abierto institucional accesible de modo libre y gratuito a trav s de internet d Distribuir copias electr nicas de la obra a los usuarios en un soporte digital 4 Derechos del autor El autor en tanto que titular de una obra que cede con car cter no exclusivo a la Universidad por medio de su registro en el Repositorio Institucional tiene derecho a a A que la Universidad identifique claramente su nombre como el autor o propietario de los derechos del documento b Comunicar y dar publicidad a la obra en la versi n que ceda y en otras posteriores a trav s de cualquier medio c Solicitar la retirada de la obra del repositorio por causa justificada A tal fin deber ponerse en contacto con el vicerrector a de investigaci n curiarte rec upcomillas es d Autorizar expresamente a COMILLAS para en su caso realizar los tramites necesarios para la obtenci n del ISBN d Recibir notificaci n fehaciente de cualquier reclamaci n que puedan formular
141. or larger cleaning area Other ideas are incorporating a mini robot to help clean or using an ultrasonic cleaning bath 44 6 3 5 With four senior mechanical engineering students including myself and two other undergraduate students we conducted two 6 3 5 Appx X exercises By using this intuitive rapid fire brainstorming technique we came up with various new solutions Functional Design Change After reviewing our idea we noticed that many people drew brushes with different patterns Therefore our redesign prospects focused on the bristle material length and geometry Other ideas were using cleaning fluid increasing force using ultrasonic vibration and increasing number of passes From these concepts we generated numerous ways of accomplishing these functions Industrial Design Change One of the best ideas was to attach a shock absorbing material that acts as a micro pneumatic damper In addition to cushioning the body it would include springs that absorb the force An analog to reduction of force is a mass spring damper system This is a proven method of absorbing force and energy For our product dissipation and redistribution of collision energy is the best way to dynamically attenuate the acoustic energy of the lid We considered adding sensors to avoid the device to collide The sensor can tell the motor circuit to change direction and avoid collision Functional Background Information Our team researched five an
142. organize and assess the customer needs regarding the Grillbot After we conducted customer interviews the importance of the customers responses was discussed The customer interviews gave us a deeper insight into the biggest issues with the Grillbot and allowed us to determine the first room of the House of Quality Customer Needs We determined all of our customer needs and then placed them into one of the following five categories User Interactions Aesthetics Portability Effectiveness and Value Then using 30 the customer ratings from our customer interview results we found an average rating of relative importance for each of the customer needs Similarly we used our customer interviews to determine the next section in the HOQ Customer Perceptions Normally the customer perceptions section would evaluate customers perceptions of our product in comparison to their perceptions of our competitors product However since there are no other grill cleaning robots we were unable to do so The customer needs section is directly related to the next section of the HOQ Metrics We put the measurable characteristics of the product that are directly related to the specified customer needs in the metrics section We also labeled each metric with a direction of improvement For example since we want to increase the mass of the Grillbot we put an arrow pointing upward Likewise since we want to decrease operating noise level we put an ar
143. oso con los derechos del autor seg n lo permitido por la legislaci n aplicable y con fines de estudio investigaci n o cualquier otro fin l cito Con dicha finalidad la Universidad asume los siguientes deberes y se reserva las siguientes facultades a Deberes del repositorio Institucional La Universidad informar a los usuarios del archivo sobre los usos permitidos y no garantiza ni asume responsabilidad alguna por otras formas en que los usuarios hagan un uso posterior de las obras no conforme con la legislaci n vigente El uso posterior m s all de la copia privada requerir que se cite la fuente y se reconozca la autor a que no se obtenga beneficio comercial y que no se realicen obras derivadas La Universidad no revisar el contenido de las obras que en todo caso permanecer bajo la responsabilidad exclusiva del autor y no estar obligada a ejercitar acciones legales en nombre del autor en el supuesto de infracciones a derechos de propiedad intelectual derivados del dep sito y archivo de las obras El autor renuncia a cualquier reclamaci n frente a la Universidad por las formas no ajustadas a la legislaci n vigente en que los usuarios hagan uso de las obras La Universidad adoptar las medidas necesarias para la preservaci n de la obra en un futuro b Derechos que se reserva el Repositorio institucional respecto de las obras en l registradas retirar la obra previa notificaci n al autor en supues
144. ot enjoy a relaxing meal eating their cheeseburgers while the robot bumped clumsily along inside the grill Again the cost was higher than many are willing to pay for a clean grill One of the biggest issues we encountered was the difficulty with cleaning the Grillbot s own brushes and body The body could be cleaned with soapy water and paper towels but there was no easy way to clean the brushes by hand Cleaning the brushes requires the use of a dishwasher which could pose an inconvenience to many Though generally easy to use a few people found the brush removal and re assembly difficult or confusing It takes significant force to press the button that releases the brush When putting the brush back on one must align it with the teeth on the rotating spindle or else it will not rotate and pop off when the motor starts which happened a couple of times One feature we did not test yet was the overheating alarm According to the product manual the Grillbot can clean in temperatures up to 250 degrees F When it exceeds that temperature it turns off and sounds an alarm telling the user to take it off the grill Next we will take these results and implement them into the House of Quality to better understand them The House of Quality analysis will help us to act on what to do next House of Quality HOQ We used our customer interviews as a basis for developing and creating a House of Quality shown in Appendix H The purpose of the HOQ is to
145. ould not detect prior to the experiments We developed an FMEA for the redesigned product and we primarily focused on the components we modified during the experiments For the experiments the two parametric interests were varying the brush length and adding weight The FMEA for the redesigned product is shown in Appendix AO The first component is the brush wheel The potential failure modes are inefficiencies misalignment and bonding failure Inefficiencies are caused when the hardware fails When the brush pattern is too short it does not penetrate much on the grill therefore its cleaning area will be small 64 Misalignment is a failure that can be caused by human error and it will not clean the grill thoroughly Lastly there could be bonding failure If the bristles are not bonded properly then the bristles will fall off When the brushes miss some of the bristles it will be inefficient The next component we are going to analyze is the brush motor shaft We added some weight during the experiments in our product if we were to add weight then the brush motor shaft will be supporting the weight The failure modes are fracture instability and loosening Using an improper material could cause fracture failure If the material is too brittle then it cannot support the weight and will break Instability and loosening failure modes could be caused by improper installation When the brush motor shaft is not stable it will not transmit eno
146. ower The result of this order of magnitude calculation is that it is physically feasible to introduce this system However because the price of a mini portable air compressor is around 30 00 and building a pressure vessel for our specs will require a metallic structure with sufficient sealants O rings will cost at least 20 00 this idea is very expensive compared to our other redesign avenues Process of Recording the Rotational Speed i We marked at the end of brush with a tape Then we turned on the device and videotapeed it with an Iphone We watched the video and counted how many times the mark has passed and recorded the corresponding time We repeated counting 3 times and averaged the values This is how we recorded the rotational speed 184 185 Test Verification with dimensions given by the Engineering sketch Measure with a ruler Verify with output torque of motor Measure Weight with a digital weight scale Test through Tensile Strength Test Measure noise with phone Application dB Measure noise with phone Application dB from customer interviews Date Demand Wish Meris Value Target Value Units Responsibility ONS w Volume 21464 201164 esa AF Term 09 09 15 D length of shafts amp m Al 04 04 15 D Rotation Rate of Wheels 313 313 j eydespersecond All ans W M 533 T JA jns w or We Brushes 599 Wm
147. plugged into a female port on the Grillbot One of the primary reasons the Grillbot was a good selection for preliminary market analysis is that the customer reviews from several sources loved the idea but had complaints on its operation We believe we can make improvements that will allow the Grillbot to endure hotter environments be more user ergonomic and remove more sediment 23 Gantt Chart and To Do List In order to organize the task distribution and effectively monitor the progress I utilized the Gantt chart tool based on a detailed to do list Appx A Tasks were distributed in sequential order of project progression To track our progress we had structured meetings on Tuesday and Thursday afternoon where we discussed our individual progression and updated the Gantt chart accordingly At these meetings we would also talk about the next stages of the project and construct a timeline for the completion of those tasks as well Literature Review The appeal of grilling is simple grilling ads flavor takes a relatively short amount of time to cook large amounts of meat 1s simple to use and can be a social bonding opportunity The ease of grilling has led to a huge market for grill related products Consumer Reports 2014 Despite the positive attributes that using outdoor grill devices for cooking can provide there is also a negative side of using grills to consider The cleaning process is meticulous and strenuous Over 70 of u
148. population demographics of grilling population grill use and other related facts concerning grill rates This article is relevant to our research because it helps to understand where why and how people are using grills We are able to hone in on the product market for the Grillbot which provides insight to answer the question Why is someone buying this product The article does not mention the how the study was conducted which immediately detracts from the credibility It also does not have a published author but rather is published by the organization itself which removes responsibility from the author In addition the HPBA organization 1s an association that receives outside funding from individuals which could bias the findings of the studies conducted Technical Sources 1 Bergman T Lavine A Incropera F amp Dewitt D 2011 Fundamentals of heat and mass transfer 7th ed John Wiley amp Sons In chapter 3 of this textbook it covers the process of heat transfer via conduction It shows how the temperature varies in solids depending on the types of materials the size of surface area 75 and the shape of material It also contains the material on heat transfer from extended surfaces In chapter 7 and 8 it talks about the details of heat convection In chapter 7 1 mainly talks about the external flow of heat transfer on flat plates cylinders and spheres Chapter 9 references techniques used to analyz
149. r corrosion can cause them Both failure modes will result in inefficiencies After we listed all the possible failure modes effects and causes we moved on to assigning severity occurrence and detection ratings We used Severity of Effect Rating Scale Occurrence Likelihood Rating Scale and Detection Likelihood Rating Scale as our reference when we are rating our own components Then we calculated the Risk Priority Number RPN for each of the failure modes This number can be calculated by multiplying the three ratings severity occurrence and detection When we calculated the RPN there were two components with an RPN higher than 100 They are the motor and the brush wheel We also listed remedies for those components that fell under the critical RPN but we mainly focused on those two components We decided to replace the motor with a more efficient motor and use different materials for the brush wheel such as stainless steel 306 because it is sturdy and has fewer tendencies to get oxidized We updated this information in the updated bill of materials Appx AP We calculated the new RPN for the components based on the remedies and listed them under the improved situation columns None of the components had an RPN higher than 50 This way the user could be satisfied with the product and also the failure can be minimized Redesigned Product After we redesigned our product we noticed a couple more failure modes that we c
150. re ignored even though the spindles are rotating What we found from doing these calculations is that by doubling the mass we will be doubling the resulting spring velocity from the energy stored in the bristles By increasing the velocity of impact as well as the friction of impact increasing the downforce is a viable way of increasing the cleaning performance The second concept was extending bristle length Our assumption s that the ends of each bristle will sweep the grille and the extended area would also sweep the grille the edges of grill specifically We measured the dimensions first We calculated the cross sectional area of one bristle strand and estimated the number of bristle strands in one bristle group We then counted the numbers of groups of bristle By multiplying those three we were able to get the cleaning area For the calculation for new brush we just need to set the target length and calculate the area of extended part Our target length is 12mm and current bristle length is Q9mm However when we were calculating the area of the side we set the length as 02mm because there would be a deformation We multiply this area by total number of brush strands We targeted the half of the bristle group will have longer length Then it gives you the cleaning area of current brush and new brush The third concept was to add cleaning fluid that will dispense through a nozzle to soak the grill surface in a soapy mixture This soapy mi
151. ristles reach areas towards the top of your tooth while the longer bristles reach to the crevices between teeth Because the bristles have different lengths they reach various areas without interfering with each other When the Grillbot moves across the grill with single length bristles it does not clean the edges of grill grates However if the brush bristles of Grillbot had different lengths the longer one will clean the edges while the short bristles would simultaneously clean the grill surface The third analogy is dental floss a cord of thin filaments used to remove dental plaque from between teeth where toothbrushes cannot reach Dental floss and Grillbot are similar because they both are trying to get rid of food residue and the objects that they clean have uneven surfaces The principle of dental floss is sliding the floss between the teeth in a reciprocating motion We can adopt it to our Grillbot by having a conveyor belt inside our product and make it move translationally The friction caused by the belt will push off the food residue and will clean the edges of the grill Water jet cleaning also inspired the team Water jet cleaning s a method that shoots water at a very high pressure The principle of it 1s to spit out high pressured water which pushes off the dirt on the grill We could adopt this idea by having a nozzle that swings slowly This method can be useful if we can have a small high pressure pump inside of our device as the
152. row pointing downward Finally we added the units associated with each metric under the direction of improvement row The next section of the HOQ is arguably the most important the interrelationships section The purpose of this section is to analyze the relationships between the customers needs and the metrics in order to easily identify how we can manipulate certain aspects of the product in order to meet customers needs We represented connections between certain metrics and customer needs through marking their intersection with either a check mark or an X For example Easy to hold and place on grill and Mass of Grillbot have a strong negative relationship the greater the mass of the Grillbot the harder it is for the user to hold and place it on the grill Therefore we placed a bold X in the cell of intersection The rating system we used involved four options strong positive medium positive medium negative and strong negative signified by a bold check mark a regular check mark a regular X and a bold X respectively Once again this section provides an easy analysis of how we can manipulate certain metrics to meet desired customer needs The next section lies directly beneath the interrelationships section and is titled the Targets Section In this section we listed our current metric values as well as our desired target values We decided to increase the mass of Grillbot because custom
153. s cleaning therefore the RPN reduced from 144 to 24 From FMEA for the redesigned product the important modifications are mostly measuring accurately and precisely so that it decreases failure modes 65 Design for Assembly The design for assembly DFA guidelines allows us to come up with different ways to make our product easier to use Using these guidelines we found three ways that will help us to lower the total part counts reduce assembly time and decrease cost Telenkom Seepersad amp Webber 2008 Combining upper shell handle and label We will reduce the total part count by combining the label handle and upper shell into one component This is recommended in DFA guideline 1 shown in Appendix AQ where it suggests minimizing part count by incorporating multiple functions into single parts When our team was disassembling the part we thought it was unnecessary to have different parts for the label handle and upper shell If we combine them together then the user will have less time to assemble the device By doing this the label label screw label washer handle screw that connects the handle and the upper shell and upper shell can be reduced to one component Telenkom et al 2008 Combining bottom shell with bottom pads For the bottom pads there are three pads that are screwed onto the bottom shell Our team chose guideline 1 minimize part count by incorporating multiple functions into a single part t
154. s of analysis Finally I learned methods of prototyping to successfully test redesign avenues and to construct simple models to simulate a much more complicated event The Grillbot was a great product to redesign because it had many interacting features that involved electrical translational and rotational energy domains In all I am very pleased with the results of our redesign and would recommend the manufacturing implementation of our concept variants so that the product can better serve the needs of the customer 71 72 ANNOTATED BIBLIOGRAPHY Market Sources 1 Customer reviews of grillbot GBU103 automatic grill cleaning robot Retrieved February 12 2015 from Amazon website http www amazon com Grillbot GBU 103 AutomaticCleaningOrange productreviews BOOH VP1PIDI refzcm cr dp see all btm ieZUT F8 amp show Viewpoints 1 amp sortBy bySubmissionDateDescending After reviewing the customer reviews on Amazon we observed that most customers found that the product is too noisy and some customers also mention that one of the brushes fell off a few of them did so on the first use One reviewer says that the screws were quite loose so they had to tighten them to prevent the brushes from falling off again However the brushes are hard to remove for cleaning and they lose bristles constantly A common theme in these reviews is that the lid of the grill must be closed otherwise it falls off As a result it bangs against the lid making
155. sers complain that cleaning the grill after use is the worst aspect of the grill process Grilling Product Reviews 2014 Hence grill cleaning is the complaint that the Grillbot aims to address Based on studies conducted by the Hearth Patio amp Barbeque Association HPBA over 80 of American households own a grill or a smoker Each household is estimated to use their grilling product on average 45 times per year In addition it is reported that the main consumer group of grills and grilling supplies is male 70 and because larger families of more than three members tend to grill more often than individuals the male consumer is most likely the head of the household HPBA 2014 The price point is also a contributing factor into who will buy the product The Grillbot is significantly more expensive at a cost of 130 than the standard wire cleaning brush at approximately 10 20 Grilling Product Reviews 2014 This information indicated that the consumer of our product will have a disposable income Because this product 1s non essential and leads to satisfaction with only marginal gains it 1s considered a delight based on the Kano Model 24 Therefore based on statistics provided from our research we know that our consumer base predominately consists of middle aged males 30 70 years in age who have the financial ability to indulge in delight commodities By knowing this we are able to factor in the target market when conduct
156. sh is equivalent to the depth of penetration This static representation again is an oversimplification of the dynamics of the rotating brush Because the depth also corresponds to the falling distance that is the amount the Grillbot falls to the grill as a result of the minimal contact with the bristles which is affected by the rotational speed stiffness of the brushes and contingent on the contract from the other brushes our model is incomplete The second response variable of surface area removed was predicted in the back of the envelope calculations as an extension of depth of penetration Using the geometries of the rod we calculated the average arc length of affectation and then multiplied that by the length of the brush The resulting surface area is therefore proportional to the predicted depth that the brushes reach Because the surface area removed is a function of the depth multiplied by a constant it is limited by the same assumptions as before in addition to others First we assume that the bristles reach every lengthwise point of the rod However because the clumps are spread over the length of the brush there still will be wet spots We also assume that the bristles will cover the whole distance of the depth which may not be the case due to jumping or sliding of the brush Results Response Variable 1 Depth of Penetration Once we ran the experiments we had to process the gathered images From our experiment
157. specialmente de la cultura estadounidense del sur El estado de Texas ofrece una de las cuatro tradiciones de barbacoa que pertenecen al cintur n de la barbacoa de los Estados Unidos 80 de los hogares estadounidenses posee una parrilla o un fumador y se estima que se utilizan en promedio al menos tres veces a la semana El departamento de Ingenier a Mec nica de la Universidad de Texas en Austin pide a los estudiantes de ltimo a o de grado realizar ingenier a inversa y redise ar un nuevo producto de consumo que ha salido recientemente al mercado Debido a la gran demanda de barbacoa y asar a la parrilla en Texas uno de los inventos m s recientes ha sido un robot de limpieza de parrilla llamado Grillbot Este producto es un dispositivo de limpieza de la parrilla automatizado Cuenta con m s de 20 piezas contiene elementos electromec nicos se ocupa de la transferencia de calor t rmico y tiene un amplio campo demogr fico de usuarios El sistema electro mec nico as como los m todos de disipaci n t rmica implementados en el Grillbot ofrece amplias oportunidades para llevar a cabo la modelizaci n anal tica y experimental en el producto Adem s dado que el producto fue 15 lanzado en enero de 2014 s lo tiene alrededor de un a o de edad La inmadurez del producto es ventajosa para encontrar problemas de dise o cr ticos que se pasaron por alto durante el desarrollo del mismo El prop sito del Grillbot es elim
158. stomer gave for the first part of the interview we noticed that noise was the biggest problem while appearance and ease of use were very good The full report of the customer interview sheets as well as the customer interview summary data is located in Appendix G In the customer needs analysis we recorded each comment the customer made as well as some of the non verbal actions we witnessed For each of e those customer voices we interpreted the actual need For each of the customer needs we ranked the importance of that need We based this importance ranking from 1 to 4 on both the customer interviews as well as our own judgment Then we compressed the many voices they expressed into the core customer needs as seen in the customer interview summary These core customer needs are then included in the House of Quality which will be the next step The general conclusions we drew from the customer needs analysis were that the Grillbot generally worked well The robot had an attractive appearance and was easy to disassemble It 29 cleaned the grills better than some expected though it took a much longer time that a hand brush Many customers really liked the automatic aspect to it that it did all the work for you Also the battery life was excellent with over an hour and a half of cleaning the battery was still half full Unfortunately the noise cost and difficulty of cleaning the Grillbot led many customers to dislike it They could n
159. sv to hold i 2 3 1 Comments Cal ese a han die Easv to clean the GrillBot 1 2 3 4 5 Comment Easv to operate figure out 1 2 3 4 Lomments 4 T Gurken 7 Value 130 Lommenis amp dll naa amp 5 Be I rout i dm mm Le nn m A A SS SSS SSS SS O What do vou like about the GriliBot Looks and clean i by Perk What do vou NOT like about the GrillBot Tos laud foo Expensive doesnt elon 2 What would vou change Make lemot cheaper Would vou buy it Whv whv not Tf not wnat woua you nay for i 320 100 m E Abe rd 3600 a vour grunne experience level i 2 3 5 Appearance 1 2 3 4 gt COMERS Noise i 1 3 4 5 Comments Effectiveness l 2 3 4 5 Comment Easv to hold 1 2 3 4 5 Lomments Easv to clean the GrillBot Comment Easy to operate figure out 1 2 3 4 5 Comments Value 130 1 2 3 4 5 Lommeni gt Overall rating 1 2 3 4 5 Le me ee ee mm mm mom mem Le A o o e XX a A O ee e lt A eS ee at ao vou ike about me uriliBot Apu pne ipe What do vou NOT like about the GrillBot sv A Es we AF What would vou change Cost j SIF Would vou buy it Why whv not Ew weh ER 11 not what would vou Dav ror t
160. te that the length variable has more effect on the result than the mass variable Response Variable 2 Surface Area Contact Our second response variable to measure is the total amount of surface area contact by the brush We used the same images as the first response variable analysis but used Photoshop to analyze the amount of pixel area removed We first changed the color scheme so that the area of the oil removed was contrasting to the area that was not affected We then selected that area and used the analysis count tool to measure the amount of pixels in an area Using that value we found as we did before the ratio of the 2 D area removed to the 2 D total area From that ratio we used the geometry of the rod to project the 2 D ratio to an averaged arc length The arc length times the length of the rod then gave us our total average surface area removed The results from those calculations are shown in Appendix AM We found that the total surface area is simply half the circumference multiplied by the length which is 9 42 in Therefore the surface area removed in each circumstance is less than 1 4 of the total possible grime deposit That being said our results indicate much more consistent sensitivities to control variable changes than the depth responses Similarly to the depth response the lowest amount of oil removed occurred when the system was low weight short brush Unlike the depth variable however the surface area removed w
161. tent issued to Rene Wichert in 2015 is for a battery operated motor in a work apparatus Battery operated direct current motors are increasingly being used as a drive in handheld work apparatus and in order to be able to use lightweight high powered electric motors a substantial electronic outlay has to be implemented It is an object of the invention to provide the operating signals which are to be evaluated for the disruption free operation of an electric motor to the control unit of the motor with little circuit complexity The electric motor of the invention includes an arrangement of field windings for driving the rotor with an electric motor wherein the field windings are successively alternately connected to an energy source in such a manner that torque acts which drives the rotor The patent is of our concern because even though we have not disassembled the Grillbot yet we know it contains three motors so the electric motor will be a large part of it Therefore we can use this source to get an idea of what we might find once we take it apart In addition as the patent is extremely recent it will probably be very useful to us further on to compare with the motors in the Grillbot and it may even help us make improvements on it 2 Ge M M 2009 U S Patent No 7462375 Elk Grove Village IL National Material Ir 71 This patent for a Method of Making a Stick Resistant Multi layer Ceramic Coating talks about the detai
162. the Grillbot 118 119 Hypothesized Functional Diagram Speaker otor 2 Brush is Cleaner gri Transmit EE Convert EE to RME T EA Convert RME to TME Power Adapter Battery EE AC EE Lane po import Stored EE ui z a 3 0 Power Button Circui Board Motor 1 Wire Motor 1 Brush 1 Hand Cleaner 8 Power ONO EE E EE Power Import Signal 92 Regulate EE EE Transmit EE Convert EE to RME AM Convert RME to TME Cleaning time setting _ Cleaning time setting EE TME z ul 2 u x 1 se 2 7 2 3 e 3 a in n i i i o o M 4 312 amp i Motor 2 Wire 3 Power On OH EE u i X LATA aa 1 ul q Temperature Convert EE to __ Power On Off j 5 E El 2 Aco ustie Acoustic E ___Temperature 8 3 2 E S 2 E s 2 S S 3 2 S Material 3 v5 Themocouple 7 gt Energy 6 Motor 3 Wi Motor 3 information Convert ThE to EE Waste ThE ZASS al Brush 3 Cleaner 0 EE Transmit EE Convert EE to RME 8 onvert RMEtoTME ur EE Electrical Energy ThE Thermal Energy Lr r 4 r va Ww w RME Rotational Mechanical Energy E ER 2 2 al 5 TME Translational Mechanical Energy ER 2 2 7 E OE Optical Energy g E 2 3 AC Alternating Current EE E a DC Direct Current EE g Structure iona Predicted Funct Appendix M Step Pat Task Necessary Tools mm cos 45 i sin 45 j cos 45 i sin 45 j
163. tles or even the water jet nozzles we will discuss the benefits of adding a water jet later in this section Then the water jet nozzles will swing changing angles over time shoot water at a larger area and clean the edges of the grill Different types of brush materials would have different friction coefficients and we could use copper steel and rubber More friction will result in better cleaning If the device were to have different brush patterns different geometry or alignment of the brushes it would be able to remove food residue on the edges of the grill due to new reachable contact areas and contact angles Since electric sensitive material can generate and also adjust friction force we decided it is the best idea To import fluid we found several ideas such as the following adding different types of pumps and flammable chemicals dispensing soap or water radially and axially on wheels adding a dispense nozzle and incorporating a water jet Flammable chemicals can be used to melt dirt stuck onto the grill However using a flammable chemical is not very feasible because it might heat up the device too much and burn it Common 1991 We could have an electrical pump to dispense fluid but it would be hard to manufacture it so it is small enough to fit inside the device 48 Electric 2015 A component that dispenses fluid would soften the food particles Once they are moisturized the device could remove them mor
164. to improve cleaning Furthermore if we have more motors it could increase the cleaning effectiveness Though in order to have an AC motor we need to have a current inverter inside of the device or a cord needs to be plugged into the wall We think it is not feasible because people usually grill outside and it is hard to find an outlet outside Additionally if we use an AC motor we will need a converter for the battery that would convert AC to DC which is an extra component From the 6 3 5 we came up with the sub function idea that converts directly from EE to TME which increases the efficiency We could use linear motors a technology HIWIN Corporation invented Linear 2013 If we had linear motors our device could clean more thoroughly because it would not skip any area Our current device moves randomly therefore it could miss some spots However the spaces between grill gratings are small Therefore we think a DC motor would be the best choice To convert RME to TME we considered using three wheeled or multi wheeled omnidirectional robots Chebyshev linkage Hoekens linkage and a slider The Grillbot currently uses a three wheeled robot which allows it to move in various directions We came up with a multi wheeled robot but this design would make it hard for the device to change direction in a 7 small space We considered those linkages because part of their motion contains linear motion We can utilize Chebyshev linkage and
165. to remove from the grill Therefore if we could make a Grillbot that had a big bath it would clean effectively Also the user would not have to suffer from loud noises which is the industrial redesign avenue Fig 8 An existing tank coverted to a ultrasonic tank using two watertight immersible ultrasonic units 153 Dental Floss Dental floss is a cord of thin filaments used to remove food and dental plaque from between teeth where toothbrushes cannot reach You break off a piece of about 18 inches long You insert floss between the teeth and gently slide the floss between them in a zigzag motion You could form a C around the teeth to get rid of food particles more effectively When the Grillbot is used the brushes do not touch the edge of grill Dental floss 1s used because toothbrushes cannot brush off between teeth Therefore we thought it was a similar situation the Grillbot does not touch the edges of grill as the toothbrush does not reach between teeth If we used a sort of sponge belt and made it slide around the grill it would get rid of food residue on the edges of grill 154 Water jet cleaning Water jet is a cleaning method where a nozzle sprays water at a high pressure to clean surfaces and materials Instead of using a brush we thought outside of the box and came up with using a water jet If we used a water jet it would clean due to high pressured water streams Our ideas of adopting this method to our dev
166. to the Main Circuit In order to obtain robust and precise dimensions we used a ruler and calipers We assumed depth y axis width x axis height z axis and inner and outer diameters as the basic dimensions For the screws we measured the nominal diameter the body diameter the total length and the length of the head We used our prior knowledge of materials manufacturing to assume the most probable form of manufacturing for each part For example the top shell is plastic and has a parting line Therefore we assumed it was injection molded For bulk orders of screws it is better to outsource Original Equipment Manufacturer OEM screws rather than make them in house For the same reason we assume other parts such as the battery charger the rubber power button cover the circuits the LCD display motors and the battery are all OEM products In addition to prior knowledge we used the patent of our product to discern materials From the patent we learned that the top shell the lower shell the pads the brush motor shafts and the brush wheels are made out of TC 895 A B BLACK This material has a low thermal conductivity and is manufactured by BJB Enterprises Woods 2012 Performing a deep analysis of each component of the Grillbot we understood why the engineers chose to use certain materials and processes for specific component Based on our bill of materials we were able to discuss possible redesign avenues Exploded View
167. too high 3 D 1 3 5 xN c Automatic function Easy storage solution Long battery life m Oo Easy to disassemble Make quieter and more affordable 15 1 amp Oo OW Automatic function Add value by increasing effectiveness and or lowering price I would change it so that individual wire Increase cleaning effectiveness for deep reach 0 brushes are longer and stretch more towards the center Doesn t take me long to clean my grill so this is unnecessary Clean faster and better than hand brush Oo 111 John L 9 Grilling experience level Easy to operate figure out 9 Overall rating 7 10 I like how well it cleans the grill Hesitates turning 11 device on 12 7 Lower the price Seems frustrated at loud beeping after he 13 manually turned it off I don t grill enough to 14 justify buying this Connor 10 1 5 n a te Effective cleaning Intuitive operation Lower the price Attractive and helpful sounds Add value E Customer Ratings Aggregate Customer 1 2 3 4 5 6 78 9 10 Avg Max Min Grilling experience level 21514 5141512 2 4 5 5 2 5 4 4 3 4 214 5 31 4 Easy to clean 3 9 Easy to operate figure out DAL 2 11211 5 1 3 Overall rating 3 3 3 2 4 2
168. top watch Appearance N f Col 15 02 15 W 00 000 2 All Observation Grillbot 128 Appendix U To do List and Gantt chart for Phase II To Do List Phase 2 Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Complete Complete Complete Complete To Do List Make the List Distribute work Gantt Chart Make the chart Plan Select Adaptive Avenues Select Adaptive Avenue Write up for Functional Redesign Avenue Write up for Industrial Redesign Avenue Brainstorming Mind Maps Industrial Mind Maps Functional 6 3 5 Industrial 6 3 5 Functional Write up for Mind Maps Write up for 6 3 5 Analogy for Functional Redesign Avenue Five Analogies Write up TIPS TIPS Write up Morphological Matrix Brainstorm Ideas Make the Matrix Write up for Morphological Matrix Design Change Concept Generation Draw Functional Redesign Concepts Draw Industrial Redesign Concepts Write up for Functional Redesign Avenue Write up for Industrial Redesign Avenue Putting them together Low Resolution Prototype Buy Materials Building Prototype Write up 129 Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Order of Magnitude Calculation Concept V
169. tos suficientemente justificados o en caso de reclamaciones de terceros Madrid a 1 de Junio de 2015 ACEPTA Fdo Maria Reina Gomez Acebo Proyecto realizado por la alumna Maria Reina G mez Acebo Fecha aos Autorizada la entrega del proyecto cuya informaci n no es de car cter confidencial AN EL DIRECTOR DEL PROYECTO Christopher G Rylander B del Coordinador de Proyectos Jes s Jim nez Octavio COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI GRADO EN INGENIERIA ELECTROMECANICA ESPECIALIDAD MECANICA APPLICATION OF MECHANICAL ENGINEERING DESIGN METHODOLOGY TO REVERSE ENGINEER AND RE DESIGN A GRILL CLEANING ROBOT Author Mar a Reina G mez Acebo Director Christopher G Rylander University of Texas at Austin Madrid May 2015 10 APPLICATION OF MECHANICAL ENGINEERING DESIGN METHODOLOGY TO REVERSE ENGINEER AND RE DESIGN A GRILL CLEANING ROBOT Author Reina G mez Acebo Maria Director Rylander Christopher Collaborating Institution The University of Texas at Austin ABSTRACT If any gastronomic treat could give the proverbially American apple pie a run for its money it might just be barbecue Barbecue has been a staple of American culture since colonial times especially Southern American culture The state of Texas offers one of the four barbecue traditions that belong to the barbecue belt of the United States 80 of
170. ugh rotational mechanical energy to the brush therefore it will be inefficient Furthermore if the connecting part is loose then the brush will fall off and it will not be able to clean the grill The motor 1s not one of the parametric interests however we found that the solder is really weak and keeps breaking during the experiments We need to solder with a stronger material so that 1t does not fail Next we calculated the RPN for each failure mode Many of them were higher than 100 except for inefficiencies and misalignment failure of the brush wheel As we did an FMEA for the original product we focused on the failure modes with an RPN higher than 100 For bonding failure we can use a stronger glue material or have a better attachment technique to attach the bristle to the brush We can prevent fracture of brush motor shaft by using different materials that are less brittle but stronger In order to prevent instability and loosening failure we need to have a precise measurement prior to manufacture Lastly we need a stronger soldering material for the motor so the connection does not fail As a result the RPN of all the failures 1s less than 100 and this will lower the chances of failure by making relevant adjustments for the product The important modification of FMEA for the original product is changing the materials of bristle to SS 306 because when copper gets oxidized it could leaves copper particles on the grill when the machine i
171. ugh the rotating wire spindles vibrational energy of the clattering grill lid and optical energy of the LED display The Grillbot operation also outputs material flow by means of the clean grill removed food particles and the hand to remove the Grillbot Lastly the information output of the Grillbot consists of a completion Beeping sound and the display of the remaining charge The sum of the energy input flows 1s equivalent to the sum of the energy output flows indicating that the energy of the system is conserved by means of the primary operating function Additionally the material flows are conserved because the dirty grill and the hand that places the Grillbot for use are also output flows The informational flows however do not follow conservational laws because the required information is not equivalent for input and output flows Predictive Cross Sectional Sketch A predictive cross sectional view that details the internal components of our device was sketched Based on our brainstorming ideas Appx K we finalized our sketch Appx L We know this device operates on electrical power which is obtained by a power outlet and stored in the battery Also we assumed there s an AC DC converter which converts AC electrical energy from the wall to DC electrical energy for the motors In our predictive cross sectional sketch the power would be delivered to the controller when the switch is pushed and the controller would send a si
172. un PINK Mark RED Maria LIGHT GREEN Mark BLUE Sean PURPLE Non J students 142 143 IMPROVING CLEAN IK E al wit TASAS 9 TUM OR or Otro 1 P CLEAN 4 glide mares x EZ 61 5 tet a Marne NER Puare Lol eC 5 es gerere inconv nicat tor Ge ILLE peer m dede 8 i Elec reife 0 ul N GRILLE 144 vv Tungsten or Rock stone 145 a yy 0 Poteet NB iere C CLE ber some longer k lf j ym d p iw GUT y Aan Grit MNONINVAS WE 2 Ins Gt A DA gallt bey n HET LEE LITT DIDA 711815 1 5118 0 2 Opa i ATA 146 147 8 lesa My yon HAS r i 1 J Ste 4 mtm ng 6 3 5 Summarization Table Industrial Redesign Avenues Noise Reduction 1 Shock Absorber on body Body material e Pads on body Need to withstand heat Mini Fluid Dashpot 2 Spring Aluminum spring e Bumper spring combo 3 Sound Absorbing Blanket e Thick blanket 4 Extend shaft length e Less surface area in collision e Change material Steel Structure support 5 Bristles on ends of brushes e Actas spring resist motion against walls 6 Wall detection e Pressure sensor e Optical IR
173. use when food residue is not cleaned well and remains on the grill the food residue will burn when the customers use it again later When food is burnt carcinogenic substances called polycyclic aromatic hydrocarbons PAHs are produced Cancer 2014 As a result our team decided on improve cleaning as our functional redesign avenue Industrial Shift Based on the customer interviews customers gave a low rating for quiet noise level and pleasing noise Many customers said the product is too loud to talk comfortably near the grill Therefore we decided the industrial redesign should be noise reduction There are two factors that make noise collision between the device and the wall of grill Appx V and the operation of the device s motors We measured noise for both Since the noise coming out from collision was louder than from the device itself our team mainly focused on reducing noise from collisions 43 Mind Maps After redesign avenues were finalized we moved on to brainstorming The brainstorming methods we used were mind mapping Appx W and 6 3 5 Appx X Industrial Redesign Avenue We began with our industrial redesign avenue noise reduction The first six concept ideas that branched out from the center were the following the grill the body of the Grillbot the motor the brush avoiding collision and external factors We considered changing the grill itself so it reduces collision noise We thou
174. ut Comments Value 130 Comments Overall rating 1 af usd soc enel je 4 L cen A better quicker 98 What ao vou like about the GriliBo futoromous Ense What do vou NOT like about the GrillBot Nese What would vou change Nose Would vou buy it Whv whv not Ni foo pas TFnor what would vou pav Tof t f o me Uti Toon a Land te vour 21111052 experience ievei i i 3 Appearance 1 2 3 O 3 Commcnt Noise 1 3 3 4 5 1 1101711121115 Effectiveness 1 Q 3 5 1 7 Easv to hold i ES X I Comments Easv to clean the GrillBot 1 2 4 5 comment Easv to operate fieure out 1 2 Q 4 5 v ommenis Value 130 2 3 Comments Overall rating 1 6 3 4 5 LS LE FTSE nn nn nun nn nl nn nm um sat do vou like about the GniiBot The overall look s cool What do vou NOT like about the GrillBot Twn ge in 4 minu ELS v 2 szgk What would vou change around 180 mu l N Would you buy it Why why not wo 415 z 11 NOL wnar would vou pav tor 11 FA 4 EA lo 4j 99 d tooa Zcke vour eruiine experience ievei i 6 3 5 6 1 2 3 3 5 comments Noise 5 Loud sounds AS Happee 5 Effectiveness 1 2 3 Ca 5 Comments Could envies needs mot weight to Chan Ea
175. ve a potential point the voltage U U of which is supplied to an evaluation unit via an adaptation device The adaptation device can be operated in two switchable adapta tion stages and is connected to a drive circuit that operates in dependence upon the rotational position of the rotor The drive circuit switches the adaptation device into the first stage having a high sensitivity or into the second stage having a low sensitivity in dependence upon the rotational position of the rotor of the motor such that the number of required analog inputs at a microprocessor in the evaluation unit can be kept low 17 Claims 4 Drawing Sheets AVA 91 United States Patent Wichert et al BATTERY OPERATED ELECTRIC MOTOR IN A WORK APPARATUS Inventors Rene Wichert Durlangen DE Gernot Liebhard Waiblingen DE Rudolf Saemann Balingen DE Assignee Andreas Stihl AG amp Co KG Waiblingen DE Notice Subject to any disclaimer the term of this patent is extended or adjusted under 35 U S C 154 b by 150 days Appl No 13 523 701 Filed Jun 14 2012 Prior Publication Data US 2012 0319626 A1 Dec 72 Foreign Application Priority Data UE 10 2011 106 578 Int Cl H02P 1 00 H02P 6 00 H02P 27 06 U S CL hs A A RED H02P 6 00 2013 01 USPC L2 318 139 318 400 15 318 144 318 721 318 823 318 801 2006 01 2006 01 2006 01 Field of
176. we had set the camera so that it was parallel with the top section of the rod From this knowledge we could extract the depth of contact from the bristles on the rod and the total surface area removed First we measured the largest distance in the z direction where the brush had removed oil from the rod in Microsoft paint by measuring the pixel counts Because we knew that the rod diameter was 4 we used a ratio of the pixel length of the displacement to the pixel length of the rod diameter Using this ratio and the known diameter we could gather an estimate for the depth 60 that the bristles reached The results from the experiment for the first response variable are shown in Appendix AM The results show that there is consistent improvement to the depth reached when at least one of the variables is increased Surprisingly though when both are increased the brushes do not penetrate as far In our back of the envelope calculations we predicted that the result from increasing both control variables would be compounding and show the greatest improvement but our experimental results suggest a negative correlation between the two variables On the other hand we did expect the greatest improvement to come as a result of increasing the length variable based on the prediction model that varies the response variable by a cubic transform of the change in length Though the results do not demonstrate the proportionality expected they do indica
177. xture will loosen stubborn grime and food particles stuck to the grill Detergents and soaps contain both hydrophobic and hydrophilic chains attached to the same molecule forcing the mixture of both polar and non polar molecules This emulsifies 182 the soap and grime mixture Forcefully agitating the soap grime emulsion by the rotation of the Grillbot s brushes will remove the dirt from the grill Helmenstine 2014 In order for the soap to emulsify the oil and water components it must wet the particles Wetting 1s the ability for a liquid to maintain intermolecular connections between a liquid and solid surface To increase wetting ability soap reduces the surface tension of water The surface tension of plain water 1s 0 073 N m while the surface tension of soapy water is approximately 0 025 N m For fourth concept we first determined the target cleaning time We recorded the rotational speed For each condition we multiplied the rotational speed by the cleaning time and the cleaning area It gives you the total cleaning area of current cleaning time and target cleaning time The order of magnitude calculation for designing a pressure jet actually led to the development of the design itself The primary limiting factor that we considered was the volume of water storage that would be portably attached to the product For our purposes we assumed a 1L liquid volume container would be the maximum capacity Another limiting factor is the load of
178. y it costs too much and requires a complicated system to generate the sound waves Therefore it 1s not a good idea To transmit RME to a large area we considered longer bristles hinged legs and a bear trap Longer bristles have a larger area to sweep off the dirt Hinged legs are another way to transmit RME but it will not be feasible to redesign because we want to keep the same volume Appx H Therefore we cannot adopt this idea We could have a brush that clamps to the grill The clamp will grip the grill and rotate around it It would increase the friction while it 1s transmitting RME However the spaces between the grill bars are small and there are different types of grills which limit its function therefore it is not feasible Lengthening the brushes is the most feasible idea because it will increase the cleaning area and is easy to manufacture It will also reduce collision noise 49 Theory of Inventive Problem Solving TIPS Based on our House of Quality we picked the feature we want to improve the length of the brush Increasing the radial length of the brush 3 affects the rotational speed 9 because it would have a larger circumference which could decrease the rotational speed Three principles we got are the other way around 13 asymmetry 4 and counter weight 8 The most feasible idea we would like to implement is principle 8 If we could adopt the aerodynamic lifting force it will have the same rotationa

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