VIRTUAL
PROTOTYPE
DFMA (DESIGN FOR MANUFACTURING&ASSEMBLE
INITIAL DESIGN
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IMPROVED DESIGN
1. Wheel Design: 3-Spoke to
5-Spoke Wheel
The wheel design was updated from a 3-spoke to a 5-spoke configuration. This change improves structural balance and load distribution, potentially reducing material stress and increasing durability. From a manufacturing perspective, 5-spoke wheels may allow for better mold filling in injection molding and offer more even cooling, reducing the risk of warping and defects. The design also standardizes with common wheel designs, enabling easier sourcing and lower unit costs at scale.
2. Handlebar Adjustment: Telescopic to Quick-Release Adjustable Handlebar
The telescopic handlebar was replaced with a quick-release adjustable mechanism. This update significantly simplifies assembly by reducing the number of small parts (e.g., locking pins or collars) and eliminating precise alignment steps. The quick-release system provides a user-friendly adjustment method with fewer tools required and shorter assembly time, supporting both ease of manufacture and enhanced usability.
3. Folding Mechanism: Hinged Clamp to Twist-Lock System
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The folding mechanism was changed from a hinged clamp to a twist-lock system. This modification reduces the number of components and mechanical joints, simplifying the assembly process and lowering the potential for misalignment or mechanical failure. The twist-lock design provides a more intuitive and secure folding method for users, while reducing labor time during manufacturing and minimizing the need for post-assembly calibration.
Human Factor
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The study of human factors aims to maximise usability, safety, and efficiency by examining how people interact with environments, systems, and products. It means creating things with the end user in mind, making sure they are easy to use, accessible, and pleasant. By considering elements like braking mechanism, fold mechanism and grip comfort, we made sure that the product is not only works as intended but also provides the user with a smooth and satisfying experience.
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DFMEA
For our ultrasonic dishwasher, we used Failure Mode and Effects Analysis (FMEA) to guarantee dependability and reduce possible problems. We were able to improve durability, safety, and general customer happiness by identifying and addressing possible failure areas early in the design phase thanks to our methodical procedure.
1. Break fails to engage effectively
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To address braking failure, we improved alignment tolerances to reduce misalignment risks, enhanced the brake pad material to minimize wear, and reinforced spring design for better durability. These changes ensure the brake system engages more reliably under varying conditions.
2. Handlebar Slips During Riding
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To mitigate handlebar slippage, we upgraded the locking mechanism with tighter fit tolerances, selected wear-resistant materials for locking components, and introduced clearer adjustment indicators. These enhancements promote a more secure and stable riding experience.
3. Clamp Fails to Lock Securely
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To improve clamp security, we redesigned the locking structure for more robust engagement, utilized materials with better wear resistance, and refined the overall geometry to reduce design flaws. These updates provide a firmer and longer-lasting locking function.
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MANUAL CALCULATION
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