Bike lock

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(→Puck Lock)
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| align="center"|'''Minimize Part Count'''
| align="center"|'''Minimize Part Count'''
| Row 1, column 2
| Row 1, column 2
-
| Row 1, column 3
+
|
 +
* The chain assembly itself contains a lot of parts (chain link, chain pin, chain spacer)
|-
|-
| align="center"|'''Minimize Assembly Surfaces'''
| align="center"|'''Minimize Assembly Surfaces'''
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|-
|-
| align="center"|'''Use Subassemblies'''
| align="center"|'''Use Subassemblies'''
-
| Row 2, column 2
+
|
 +
* The chain can be assembled separate from the main housing assembly
| Row 2, column 3
| Row 2, column 3
|-
|-
| align="center"|'''Mistake-Proof'''
| align="center"|'''Mistake-Proof'''
-
| Row 2, column 2
+
|
 +
* Parts of the main housing assembly have features that allow only one way of assembly
| Row 2, column 3
| Row 2, column 3
|-
|-
| align="center"|'''Minimize Fasteners'''
| align="center"|'''Minimize Fasteners'''
-
| Row 2, column 2
+
|
-
| Row 2, column 3
+
|
 +
* There are fasteners between each chain link
|-
|-
| align="center"|'''Minimize Handling'''
| align="center"|'''Minimize Handling'''

Revision as of 09:24, 2 February 2014

Contents

Executive Summary

Product Stakeholder Analysis

Product Usage Study

Bill of Materials

U-Lock

Exploded View of U-Lock
Exploded View of U-Lock



Part # Name Quantity Subassembly Mass [g] Function Material Manufacturing Process Image
1 Rubber Shielding 1 N/A 68 Provides weatherproofing for the U-Bar. It keeps dirt and grime out and prevents scratches. In comparison to the U-Bar it is plush and nice to the touch. Rubber Extrusion
2 U-Bar 1 N/A 330 Can be placed around the chosen locking surface and the bike frame. This is then inserted into the base of the U-Lock and secures the bike to the locking surface. Steel Extruded, Bent, Cut
3 U-Bar Clamp Attachment 1 Bike Frame Clamp 15 Provides nice mating surface for U-Bar and bike frame bracket. Plastic Injection Molding
4 Frame Attachment Screws and Nuts 4 Bike Frame Clamp 1 Screws and nuts used to press clamp edges together around the U-Bar. Steel Off the Shelf
5 U-Bar Frame Attachment Clasp 1 Bike Frame Clamp 13 Nicely holds onto the U-Bar and connects to a base piece that can be attached to a bike frame. Plastic Injection Molding
6 U-Bar Frame Attachment Locking Tab 1 Bike Frame Clamp 4 Tab presses over edge of Clamp attachment on the U-Bar to secure it to the bike frame. Plastic Injection Molding
7 U-Bar Frame Attachment Spring 1 Bike Frame Clamp <1 Spring sits under clasp and provides force on clasp to keep Lock attached to frame attachment. Steel Off the SHelf
8 Frame Attachment Joining Screw 1 Bike Frame Clamp <1 Fastens the two major parts of the frame bracket together Steel Off the Shelf
9 Frame Bracket Base 1 Bike Frame Clamp 17 Holds clasp. Has specific points of rotation so one can change the orientation of the clasp as it connects to the bike. Represents half of the frame bracket clamp. Plastic Injection Molding
10 Mating Pad 2 Bike Frame Clamp 2 Snap in part is smooth and offers a nice mating surface between the clamp and the bike frame (Not Pictured), and the U-Lock and clamp. Plastic Injection Molding
11 Bike Frame Bracket Clamp 1 Bike Frame Clamp 18 Part is placed around bike frame and fastened to the rest of the bracket via screws. Second half of frame bracket clamp. Plastic Injection Molding
12 Locking Bars 2 Locking Mechanism 26 Bars fit into notches cut into the U-Bar. When they are in place they secure the U-Bar in place and prevent its removal. The hooks on either edge sit on nubs that rotate when the key is turned, sliding the locking bars back and forth. Brass Forged
13 Lock Component Housing Cylinder 1 Lock Mechanism 28 Neatly holds all the parts necessary to actually lock the lock. It has slots cut such that one cannot insert the lock upside down, tracks for the lock bars to slide on, and is designed such that all force imparted to the lock in an attempt to shock it open are directed around the lock bars. Plastic Injection Molding
14 Lock Housing 1 Lock Mechanism 15 Housing is made to nicely keep the lock in place inside of the component housing cylinder. It has a tab to prevent incorrect insertion of lock. Brass Off the Shelf
15 Rubber Grommet 2 N/A <1 Acts as both a seal to prevent dirt or water from entering the lock component housing cylinder, as well as a cushion to protect the cylinder from rubbing directly against the U-Bar Rubber Stamping
16 Lock Stopper Pin 2 Lock Mechanism <1 Grooves in the lock housing fit around these spring loaded pins. When the key is concerned, These pins are compressed and allow the lock to turn. Brass Stamping
17 Pin Housing 1 Lock Mechanism 8 Housing has space for spring and pins as well as the stopper pins and springs. Has a slot for a key to be inserted. Pin Housing will rotate around inside the lock housing. Brass Off the Shelf
18 Pin Springs 12 Row 1, column 4 Row 1, column 5 Pins sit on top of these springs. When the key is inserted and turned, these springs will compress or extend to get all the pins to the same height so the pin housing can rotate. They will return to their natural length after the key is removed. Row 1, column 7 Row 1, column 8 Row 1, column 9
19 Pins 8 Row 1, column 4 Row 1, column 5 These pins are each individually made with notches at a different height. The height of the notch corresponds to the pattern on the key. The correct key will line up with the notches, allowing the pins to be moved out of the way, allowing the pin housing. Row 1, column 7 Row 1, column 8 Row 1, column 9
20 Plastic Endcap 2 N\A 13 Acts as a weatherproofing seal for the outer casing of the lock base. It also seals off the ends of the lock base via a tight fit, discouraging the user from tampering with the internals of the lock. Adds a stylistic element to the lock. Soft Plastic Molding
21 Rubber Shock Absorber 2 N\A 4 Part acts as a weatherproofing seal as well as a shock absorber. Cushions any force that is applied to the ends of the lock. This prevents the lock from being bumped open. Rubber Stamping
22 Lock Bar Actuator 1 Row 1, column 4 Row 1, column 5 Slides into grove on back of pin housing. When pin housing rotates, this part rotates as well. The Lock Bars are attached to the nubs on top and turning the pin housing causes the lock bars to slide from unlocked to locked. Brass Row 1, column 8 Row 1, column 9
23 Outer Housing 1 Lock Housing 127 A powder coated outer case that neatly houses the entire lock assembly. Has holes in it to accomodate the U-Bar ans well as a small hole in it, presumably for assembly alignment purposes. Coating adds plesant feel in comparison to unfinished steel. Steel Stamping and Welding
24 Key 5 N\A 6 Key is specially made to line up with each of the pins in a specific lock. The track pulls the pins into the correct position, which allows the lock to rotate. Steel and Plastic Row 1, column 8

Puck Lock

Exploded View of Puck Lock
Exploded View of Puck Lock


Part # Name Quantity Subassembly Mass Function Material Manufacturing Process Image
1 Row 1, column 2 Row 1, column 3 Row 1, column 4 Row 1, column 5 Row 1, column 5 Row 1, column 7 Row 1, column 8 Row 1, column 9
2 Row 1, column 2 Row 1, column 3 Row 1, column 4 Row 1, column 5 Row 1, column 5 Row 1, column 7 Row 1, column 8 Row 1, column 9
3 Row 1, column 2 Row 1, column 3 Row 1, column 4 Row 1, column 5 Row 1, column 5 Row 1, column 7 Row 1, column 8 Row 1, column 9
4 Row 1, column 2 Row 1, column 3 Row 1, column 4 Row 1, column 5 Row 1, column 5 Row 1, column 7 Row 1, column 8 Row 1, column 9
5 Row 1, column 2 Row 1, column 3 Row 1, column 4 Row 1, column 5 Row 1, column 5 Row 1, column 7 Row 1, column 8 Row 1, column 9
6 Row 1, column 2 Row 1, column 3 Row 1, column 4 Row 1, column 5 Row 1, column 5 Row 1, column 7 Row 1, column 8 Row 1, column 9
7 Row 1, column 2 Row 1, column 3 Row 1, column 4 Row 1, column 5 Row 1, column 5 Row 1, column 7 Row 1, column 8 Row 1, column 9
8 Row 1, column 2 Row 1, column 3 Row 1, column 4 Row 1, column 5 Row 1, column 5 Row 1, column 7 Row 1, column 8 Row 1, column 9
9 Row 1, column 2 Row 1, column 3 Row 1, column 4 Row 1, column 5 Row 1, column 5 Row 1, column 7 Row 1, column 8 Row 1, column 9
10 Row 1, column 2 Row 1, column 3 Row 1, column 4 Row 1, column 5 Row 1, column 5 Row 1, column 7 Row 1, column 8 Row 1, column 9
11 Row 1, column 2 Row 1, column 3 Row 1, column 4 Row 1, column 5 Row 1, column 5 Row 1, column 7 Row 1, column 8 Row 1, column 9
12 Row 1, column 2 Row 1, column 3 Row 1, column 4 Row 1, column 5 Row 1, column 5 Row 1, column 7 Row 1, column 8 Row 1, column 9
13 Row 1, column 2 Row 1, column 3 Row 1, column 4 Row 1, column 5 Row 1, column 5 Row 1, column 7 Row 1, column 8 Row 1, column 9

DFMA

U-Lock

Design for Manufacture Guidelines
Design Objective Strengths Weaknesses
Minimize Part Count
  • Most parts fit together without the use of fasteners
  • The U-bar clamp assembly is not needed for the U-Lock to function properly as a bike lock and it is unnecessary if the attachment assembly is not used to attach the U-Lock to the bike
Standardize Components
  • Housing for the locking assembly is symmetric and the components used on each side are identical
  • Most of the plastic components are unique and require separate molds
Commonize Product Line
  • All of the plastic parts are manufactured through injection molding, minimizing job training
  • Holes on multiple components line up for easy alignment when assembling
Standardize Design Features
  • Housing for the locking assembly is symmetric
  • Plastic components are unique and would each require their own molds
Keep Designs Simple
  • Design is composed of two main parts: the locking assembly and the U-bar assembly
  • Attachment assembly is not necessary for the U-Lock to function as a lock
Multifunctional Parts
  • Outer metal casing acts as housing, weatherproofing, and protection for the locking assembly
Ease of Fabrication
  • Components are mainly comprised of plastic and steel
  • Housing for the locking assembly is symmetric
Avoid Tight Tolerances
  • Tolerances are not too tight because there is some slop between the U-bar and the locking mechanism
  • If tolerances are too tight, the U-bar/locking assemblies do not fit together rendering the lock useless
Minimize Secondary and Finishing Operations
  • Injection molded plastic parts do not require any secondary operations
  • Metal coloring is done through powder coating
Take Advantage of Special Process Properties
  • Powder coating is used to color the steel
  • Plastic components are colored during the injection molding process


Design for Assembly Guidelines
Design Objective Strengths Weaknesses
Minimize Part Count
  • Clamping and attachment assemblies are not needed for the U-Lock to function as a bike lock
Row 1, column 3
Minimize Assembly Surfaces Row 2, column 2 Row 2, column 3
Use Subassemblies
  • Lock housing assembly and the U-bar can be assembled and tested separately before being put together for the final product
  • The actual locking assembly, which is bought off the shelf, is assembled separately before being put into the lock housing assembly
Row 2, column 3
Mistake-Proof
  • In the lock housing assembly each component has holes that are used to align the components during assembly
  • U-bar is symmetric and will fit into the locking assembly no matter which prong is on the right/left
Row 2, column 3
Minimize Fasteners
  • Most parts fit together without the use of fasteners
  • The only fasteners are used in the clamping assembly
Row 2, column 3
Minimize Handling Row 2, column 2 Row 2, column 3
Minimize Assembly Direction Row 2, column 2 Row 2, column 3
Provide Unobstructed Access Row 2, column 2 Row 2, column 3
Maximize Assembly Compliance Row 2, column 2 Row 2, column 3

Puck Lock

Design for Manufacture Guidelines
Design Objective Strengths Weaknesses
Minimize Part Count
  • There are very few unique parts in the total assembly
  • There are pins and spacers between every link to hold them together
  • The links themselves are custom and not a standard chain or cable
Standardize Components
  • A standard roll pin size is used to hold the main housing together
Row 2, column 3
Commonize Product Line
  • Parts have features that allow for only one way to assemble them, preventing incorrect assembly and specialized training
Row 2, column 3
Standardize Design Features
  • Many of the parts used in the design are repeated (chain links, chain pins, chain spacers)
Row 2, column 3
Keep Designs Simple Row 2, column 2 Row 2, column 3
Multifunctional Parts
  • The main casing acts as protection for the locking assembly, storage for the chain, and housing for the locking mechanism
Row 2, column 3
Ease of Fabrication Row 2, column 2 Row 2, column 3
Avoid Tight Tolerances
  • Spacers on the chain links help stiffen lateral motions in the chain, allowing for looser tolerances when attaching the links
Row 2, column 3
Minimize Secondary and Finishing Operations Row 2, column 2 Row 2, column 3
Take Advantage of Special Process Properties
  • Powder coating process used to color metals
  • Color added during injection molding for plastics
Row 2, column 3


Design for Assembly Guidelines
Design Objective Strengths Weaknesses
Minimize Part Count Row 1, column 2
  • The chain assembly itself contains a lot of parts (chain link, chain pin, chain spacer)
Minimize Assembly Surfaces Row 2, column 2 Row 2, column 3
Use Subassemblies
  • The chain can be assembled separate from the main housing assembly
Row 2, column 3
Mistake-Proof
  • Parts of the main housing assembly have features that allow only one way of assembly
Row 2, column 3
Minimize Fasteners
  • There are fasteners between each chain link
Minimize Handling Row 2, column 2 Row 2, column 3
Minimize Assembly Direction Row 2, column 2 Row 2, column 3
Provide Unobstructed Access Row 2, column 2 Row 2, column 3
Maximize Assembly Compliance Row 2, column 2 Row 2, column 3

FEMA

DFE

Group

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