Bike pump
From DDL Wiki
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- | | 1 ||Screw||5||4||Holds base support (#8) in place to metal base (#31)||Steel|| | + | | 1 ||Screw||5||4||Holds base support (#8) in place to metal base (#31)||Steel||Thread rolling|| [[Image:x01.jpg|thumb|100x100px|center|Screw]] |
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| 2 ||Nut||5||1||Attaches screws (#1) to metal base (#31)||Steel||***|| [[Image:x02.jpg |thumb|100x100px|center|Nut]] | | 2 ||Nut||5||1||Attaches screws (#1) to metal base (#31)||Steel||***|| [[Image:x02.jpg |thumb|100x100px|center|Nut]] |
Revision as of 10:06, 24 September 2012
Contents |
Executive Summary
This will be a brief executive summary that describes the key findings and recommendations.
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Product Stakeholders
We have identified possible needs and wants for all possible stakeholders. The identified needs are those needs that are essential in order to encourage the stakeholder to use it. The identified wants are additional features that may benefit the stakeholder, however, they are not vital to the use of the product. For the purpose of this study, the consumer is the person pumping up the bike tire, not necessarily the bike owner.
Stakeholder Needs and Wants | ||
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Stakeholder | Needs | Wants |
Consumer |
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Retailer |
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Manufacturer |
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Shipping & Transportation |
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Product Use Study
This is where we will document in detail how the product is used, step by step, and summarize findings from our user studies with photo documentation.
Product Mechanical Function
User Input
The user connects the bike pump to the bike tire using the nozzle and locking mechanism. This creates a seal between the pump (from the air flow valve) and the bike tire, allowing for air to be pushed into the tire without losing some to the external environment. Once this seal is created, the pressure gauge shows the current air pressure in the tire and hose (up to the air flow valve). If this pressure is not the desired air pressure, the user lifts up the handle of the pump, filling the chamber with air, and then depresses the handle compressing the air. Once fully depressed, the user will again evaluate the current tire pressure and determine if it is still undesirable. Once the air pressure in the tire is sufficient, the user unlocks the nozzle and removes it from the tire, which contains its own sealing mechanism as to not lose air.
Airflow
When the user connects the bike pump to the bike tire, air flows through the hose to the pressure gauge and stops at the air flow valve at the base of the main chamber (which works using a compression spring). When the user pulls up the handle, air is drawn in from the top of the chamber where there is no sealing device and flows past the piston head, which has a rubber o-ring that acts somewhat like a valve due to part geometry allowing air to flow past it on an upstroke but creating a seal on the downstroke, and stops at the air flow valve. Once the chamber is filled with air, the user depresses the handle, compressing the air in the chamber. Once the air pressure in the chamber is greater than the force from the spring holding the air flow valve in place the spring depresses, allowing air to flow from the chamber into the bike tire. When the handle is fully depressed and there is no more air in the chamber, the spring re-extends, sealing the air in the tire and hose allowing the user to draw more air into the chamber by pulling up the handle again and repeating the process. When the user unlocks the nozzle and removes it from the tire, the air left in the hose is lost to the environment and the tire creates it's own seal to keep air in.
Assembly
This is where we will have information/photo about the major assembly.
An exploded view of the floor bike pump will be inseted here... with all components labeled.
Sub-Assembly
We may need to include detailed sub-assembly photos and information here.
This is where we will insert exploded views of each internal sub-assembly with labeled components and a brief summary of each sub-assembly function.
Bill of Materials
The following is a bill of materials from the bike pump dissection. The parts can be sorted based on part number, quantity, weight or material by clicking on the appropriate tab at the top of the table.
Part Number | Name | QTY | Weight (g) | Function | Material | Manufacturing Process | Image |
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1 | Screw | 5 | 4 | Holds base support (#8) in place to metal base (#31) | Steel | Thread rolling | |
2 | Nut | 5 | 1 | Attaches screws (#1) to metal base (#31) | Steel | *** | |
3 | Rubber readout cover | 1 | 30 | Holds plastic readout cover (#4) in place above pressure gauge mechanics (#23) | Rubber | Injection Molding | |
4 | Plastic readout cover | 1 | 12 | Provides clear screen and protection to number dial readout (#10) | Plastic | Injection Molding | |
5 | Metal connection valve tip | 1 | 5 | Holds rubber connection valve tip (#6) in place | Aluminum | Press Molding + Threading | |
6 | Rubber connection valve tip | 1 | 2 | Creates seal onto bike tube valve | Rubber | Injection Molding | |
7 | Air hose holder (double) | 1 | 12 | Holds air hose (#32) to main tube (#30) during storage | Plastic | Injection Molding | |
8 | Plastic base support | 1 | 10 | Reduces cantilever stresses on outer arm tube | Plastic | Injection Molding | |
9 | #7 O-Ring | 2 | < 1 | Provides necessary friction to hold the double air hose holder (#7) onto outer arm tube (#30) and allow for vertical movement along axis of tube | Rubber | *** | |
10 | Readout number dial | 1 | 3 | Provides a quantified tire pressure readout | Aluminum | Sheet Stamped | |
11 | Readout needle | 1 | < 1 | Displays the quantified tire pressure on (#10 | Aluminum | Press Stamped | |
12 | #13 O-Ring | 2 | < 1 | Provides seal on bike tube inside the pump stabalizer (#13) | Rubber | Injection Molding | |
13 | Pump stabalizer | 1 | 13 | Allows metal rod (#19) to move within the main tube (#30) | Plastic | Injection Molding | |
14 | Piston head | 1 | 8 | Acts as a pump to draw in air within the main tube (#30) and then compress the air | Plastic | Injection Molding | |
15 | Tube connector | 2 | 4 | Connects hose (#32) to nozzle (#***) and to the metal base (#31) | Plastic | Injection Molding | |
16 | Air hose holder (single) | 1 | 2 | Holds air hose (#32) to main tube (#30) during storage | Plastic | Injection Molding | |
17 | Handle bar | 1 | 127 | Allows user to apply downward force to draw and compress air in the main tube (#30) | Plastic | Injection Molding | |
18 | End cap | 2 | 6 | Provides a covering to the ends of the handle bar | Plastic | Injection Molding | |
19 | Metal rod | 1 | 174 | Connects piston head (#14) to the handle bar (#17) | Steel | Extrusion + Crimp | |
20 | Stopper | 1 | < 1 | Blocks airflow during upstroke | Rubber | Injection Molding | |
21 | Spring | 1 | < 1 | Pushes up stopper | Steel | Coiled Wire | |
22 | O-Ring | 1 | < 1 | Creates seal | Rubber | Injection Molding | |
23 | Pressure gauge mechanics | 1 | 50 | Converts air pressure to angular displacement | Copper | *** | |
24 | Small screw | 2 | < 1 | Fixes pressure gauge housing | Steel | *** | |
25 | Air flow director | 1 | 49 | Guides air flow from piston to hose | Plastic | Injection Molding + Threading | |
26 | #27 O-Ring | 1 | < 1 | Provides a seal to the hose-to-nozzle connector (#27) | Rubber | Injection Molding | |
27 | Hose-to-nozzle connector | 1 | < 1 | Allows air to flow from hose to nozzle | Plastic | Injection molding | |
28 | Seal between #25 & #29 | 1 | < 1 | Provides a seal between the air flow director (#25) and the base-to-hose (#29) | Rubber | Injection Molding | |
29 | Base-to-hose connector | 1 | 7 | Provides a connection between hose (#32) and air flow director (#25) | Plastic | Injection Molding | |
30 | Main tube | 1 | 238 | House piston | Steel | Injection Molding + Threading | |
31 | Metal base | 1 | 540 | Provides counter force from upstroke | Steel | Molded + Drill Pressed | |
32 | Hose | 1 | 83 | Encloses from base to nozzle | Rubber | Extrusion | |
33 | Weighted handle insert | 1 | *** | *** | Aluminum | Lathed + ??? | |
34 | Valve connection housing | 1 | *** | Gripping surface | Plastic | Injection Molding | |
35 | Valve channel | 1 | *** | Channels air through handle | Plastic | Injection Molding | |
36 | Tire interface valve | 1 | *** | Puts air in tire | Steel | *** | |
37 | Readout housing | 1 | *** | Protection of pressure gauge | Steel | Press Molded | |
38 | Piston chamber end cap | 1 | *** | Fixes main tube to base | Steel | Molded? + *** |
Design for Manufacture and Assembly (DFMA)
DFMA is a combination of two practices, Design for Manufacture (DFM) and Design for Assembly (DFA). DFM is the method of designing part so that they're manufacturing processes are simplest, and DFA is the method of designing parts that will lead to a simple assembly process at the plant or by the user.
Manufacturing
The competitor product we analyzed displayed numerous positive manufacturing features that would minimize cost and complexity. The overall design is surprisingly simple, a result of combining features into single parts where possible, using only a few different materials, and minimizing the overall part count. From a manufacturing standpoint, all components are very successfully produced, but the part that could use the most improvement is the piston chamber end cap (#38) for it involved several manufacturing processes and an additional painting process not seen on any other parts.
Below are some of the DFM Guidelines and the observations we made of how our competitor designed their product with those guidelines in mind and some areas we believe they could improve.
Design for Manufacturing Features and Improvements | ||
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Design Objective | Strengths | Areas of Improvement |
Minimize Part Count |
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Standardize Design Features |
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Keep Designs Simple |
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Multifunctional Parts |
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Ease of fabrication |
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Avoid Tight Tolerances |
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Minimize Secondary & Finishing Operations |
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Assembly
Assembly of the competitor's product is not the consumer's responsibility and occurs prior to the retail stages in the supply chain. The product requires tools and fasteners only where the piston chamber attaches to the base, and nearly all of the remaining interfaces are threaded. While minimizing toolage, this raises many challenges with orientation and radial symmetry where the assembly process could be made clearer. The variety of O-rings, springs, and cylinder diameters is another weakness that has room for improvement.
Due to the assembly process being deliberately separated from the consumer, ease of assembly is not a high priority and leaves room for redesign towards simplicity.
Design for Assembly Features and Improvements | ||
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Design Objective | Strengths | Areas of Improvement |
Minimize Part Count |
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Minimize Assembly Surfaces |
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Use Sub-assemblies |
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Mistake-Proof |
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Minimize Fasteners |
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Minimize Handling |
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Minimize Assembly Direction |
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Provide Unobstructed Access |
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Maximize Assembly Compliance |
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Failure Modes & Effects Analysis (FMEA)
- NEED TO INCLUDE INTO AS TO WHAT FMEA IS
- INCLUDE THE SCALE USED TO DETERMINE S/O/D VALUES
- THEN, ADD TO REFERENCE SECTION THE SOURCE FOR THE SCALE
Failure Modes and Effects Analysis - Floor Bike Pump | |||||||||
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Item & Function | Failure Mode | Effects of Failure | S | Causes of Failure | O | Design Controls | D | RPN | Recommended Actions |
Valve Nozzle Connector | Air leaking out of wheel | Bike tube loses air | 3 | Misalignment to valve | 2 | Check if it locks | 2 | 12 | Something to help user better secure nozzle properly |
Does not lock | No air transfer into wheel | 3 | User not using it correctly | 2 | Check if it locks | 3 | 18 | Something that does not use a lock, Make it easier to lock | |
Valve may not fit | No air transfer into wheel | 1 | Wrong valve type | 4 | Check if it locks | 4 | 16 | Make a universal valve, Provide adapters | |
Pressure Gauge | Air leaking out of wheel | Won't display pressure | 2 | Broken gauge | 1 | Test in manufacturing plant | 2 | 4 | Better pressure gauge tube seal, Different pressure reading technique |
Incorrectly calibrated | Displays incorrect pressure reading | 2 | Dropping gauge, Manufacturing error | 1 | Test in manufacturing plant | 7 | 14 | -- | |
Handle rod | Bends | Can not apply downward force, Breaks rod | 5 | Bars are physically bent forward and not down, Damaged, Improper use | 2 | -- | 7 | 70 | Stronger rod |
Tube | Air leaking out of wheel | Loss of air from tire | 3 | Misuse, Damage | 3 | -- | 4 | 36 | Tube wrapped in durable material |
After analyzing the different failure modes, we have concluded that this product has a very low failure risks and therefore low risk of harm to the user. This is due to the simplicity of the design and that our product is strictly mechanical; electrical connections would most likely add more failure modes to the product. On the other hand, this product deals with high air pressure situations so it is also a delicate instrument which comes with delicate parts. The connection valve has the most parts and therefore the most chances of failing when being used. At the same time, a lot of failures may occur due to the high air pressure which is invisible to the user.
Design for Environment (DFE)
Design for Environment (DFE) can help bring focus to specific areas when improving a design. By analyzing the entire life cycle, the areas of the largest impact can be determined and minimized.
Design for Environment | ||
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-- | Production | Use |
Item Consumed | Bike Pump | Bike |
Sector # and Name | #339920: Sporting and athletic goods manufacturing | #336991: Motorcycle, bicycle, and parts manufacturing |
Reference Unit | 1 Bike Pump | 1 Bike |
Units consumed per product life | 1 | 1 |
Cost Per Unit* | $39.04 | $234.27 |
Lifetime Cost* | $39.04 | $234.27 |
Sector mtCO2e per $1M | 613 | 543 |
Implied mtCO2e per product life | 0.0239 | 0.1272 |
CO2e Tax @ $30/mtCO2e | $0.72 | $3.82 |
*2002 USD
Production
Using the sporting and athletic goods manufacturing sector of EIO-LCA, we were able to estimate the environmental impact of producing the bike pump. The bike pump costs $50 today, which is about $39.04 in 2002. Power generation and supply has the largest contribution to the 613 mtCO2e per 1 million dollars spent in the sporting and athletic goods manufacturing category. Therefore we can estimate that for every bike pump produced 0.0239 mtCO2e is released into the environment, resulting in a minor $0.72 tax per pump.
Sector #339920: Sporting and athletic goods manufacturing
Economic Activity: $1 Million Dollars
Displaying: Greenhouse Gases
Number of Sectors: Top 10
Use
If the consumer purchases a bike pump, we can assume that they own at least one bike. Therefore we used the EIO-LCA Motorcycle, bicycle, and parts manufacturing sector to study the environmental impact of use of the pump. We estimated that today the average bike costs $300 which equates to about $234.27 in 2002. Our analysis approximated a small $3.82 tax per bike.
Sector #336991: Motorcycle, bicycle, and parts manufacturing
Economic Activity: $1 Million Dollars
Displaying: Greenhouse Gases
Number of Sectors: Top 10
Group Dynamic
Team Leader: Dinesh Ayyappan
DFMA Lead: Patrick Hogan
FMEA Lead: Jonathan Wong
DFE Lead: Amber Ohiokpehai
Wiki Page Programmer/Report Compilation: Lauren Milisits
References
This is where we should list any references that we used throughout the process of our report.